2000 DODGE NEON steering

Connector
Name/NumberColor Location Fig.
Oxygen
Sensor 1/2
Downstream
(2.0L)GY Right Rear of
Engine22
Park/Neutral
Position
Switch (ATX)BK On
TransmissionN/S
Passenger
AirbagYL Left Side of
Instrument
Panel25
Passenger
Cylinder Lock
SwitchBK At
Passengers
Door33
Passenger
Door Lock
MotorBK At
Passengers
Door33
Passenger
Door Lock
SwitchBK At
Passengers
Door33
Passenger
Power MirrorBL At
Passengers
Door33
Passenger
Power
Window MotorBK At
Passengers
Door33
Passenger
Power
Window
SwitchGY At
Passengers
Door33
Power Mirror
SwitchGY At Drivers
Door34
Power
Steering
Pressure
SwitchGY Left Rear of
Engine
CompartmentN/S
Powertrain
Control
Module - C1BK Left Fender
Side Shield21
Powertrain
Control
Module - C2BK Left Fender
Side Shield19
PRNDL Lamp BK At Center
Console25
Proportional
EVAP/Purge
SolenoidBK Left Rear of
Engine
Compartment19
Radiator Fan
MotorBK Front of
Engine
Compartment19Connector
Name/NumberColor Location Fig.
Radio - C1 BK Rear of Radio 24
Radio - C2 GY Rear of Radio 24
Rear Window
Defogger
SwitchBK Center of
Instrument
Panel24
Remote
Keyless Entry
ModuleBK Center of
Instrument
Panel24
Right Back-Up
LampBK At Lamp 31
Right City
LampGY At Lamp N/S
Right Front
Door SpeakerBK At Drivers
Door34
Right Front
Fog LampBK At Lamp N/S
Right Front
Turn Signal
LampNAT At Lamp 20
Right Front
Wheel Speed
SensorBK At Right Front
Wheel
Opening20
Right
HeadlampBK At Lamp 20
Right
Headlamp
Leveling MotorGY Rear of right
HeadlampN/S
Right
Instrument
Panel SpeakerBK At Speaker 25
Right License
LampNAT At Lamp 32
Right Rear
Door Lock
MotorBK At Motor 35
Right Rear
Fog LampGY At Lamp 32
Right Rear
SpeakerBK At Speaker 30
Right Rear
Turn Signal
LampGY At Lamp 31
Right Rear
Wheel Speed
SensorBL At Right Rear
Wheel
OpeningN/S
Right
Repeater
LampBL At Lamp 18
8W - 90 - 24 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

NOTE: Engine mount must be installed in the orig-
inal position on body frame rail. If mount was not
marked or frame rail was replaced, perform the fol-
lowing procedure.
(2) Perform the following procedure if mount posi-
tion was not previously marked or the frame rail was
replaced:
a. Insert new mount loosely in frame rail.
b. Align the four holes in the mount with the mat-
ing holes in the rail such that the holes are concen-
tric (frame rail holes centered in the mount holes).
c. Using a permanent ink marker or equivalent,
mark the position of engine mount to the body frame
rail while maintaining mounting hole concentricity.
(3) Ensure the mount maintains originally marked
position and install mount bolts. Tighten bolts to 28
N´m (250 in. lbs.) (Fig. 19).
(4) Install engine mount bracket. Refer to proce-
dure in this section.
(5) Install bolt attaching right engine mount to
bracket and tighten to 118 N´m (87 ft. lbs.) (Fig. 18).
(6) Remove support from under engine.
(7) Install upper and lower engine torque struts.
Refer to procedure in this section.
(8) Install crankshaft damper. Refer to procedure
in this section.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System for procedure.
ENGINE MOUNT BRACKETÐRIGHT
REMOVAL
(1) Remove upper and lower torque struts. Refer to
procedure in this section.(2) Remove power steering/air conditioning belt.
Refer to Group 7, Cooling System, Accessory Drive
Belts for procedure.
(3) Support engine with a suitable jack.
(4) Remove engine mount through bolt access plug
(Fig. 20)
(5) Remove right engine mount to bracket through
bolt (Fig. 21).
(6) Remove engine mount bracket attaching bolts
(Fig. 22).
(7) Bracket removal requires engine to be raised
slightly to obtain engine-to-body clearance.
INSTALLATION
(1) Install engine mount bracket and tighten bolts
to 61 N´m (45 ft. lbs.) (Fig. 22).
(2) Install bolt attaching engine mount to bracket
(Fig. 21). Tighten bolt to 118 N´m (87 ft. lbs.).
(3) Install mount bolt access plug (Fig. 20).
(4) Remove support from under engine.
(5) Install power steering/air conditioning belt.
Refer to Group 7, Cooling System, Accessory Drive
Belts for procedure.
(6) Install upper and lower torque struts. Refer to
procedure in this section.
Fig. 19 Engine MountÐRight
1 ± SNUBBER PAD
2 ± RIGHT ENGINE MOUNT
3 ± BOLTS
Fig. 20 Engine Mount Bolt Access Plug
1 ± CRANKSHAFT BOLT ACCESS PLUG
2 ± RIGHT MOUNT BOLT ACCESS PLUG
3 ± FASCIA
4 ± SPLASH SHIELD
9 - 24 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(4) Discharge air conditioning system, if equipped.
Refer to Group 24, Heating and Air Conditioning for
procedure.
(5) Disconnect the following: air intake duct at
intake manifold, throttle cables, electrical connectors
from throttle body and air cleaner housing.
(6) Remove air cleaner housing assembly.
(7) Remove upper radiator hose and fan module.
Refer to Group 7, Cooling System for procedure.
(8) Remove lower radiator hose.
(9) Disconnect automatic transmission cooler lines
and plug, if equipped.
(10) Disconnect shift linkage, electrical connectors,
and clutch cable, if equipped with manual transaxle.
(11) Disconnect engine wiring harness.
(12) Disconnect positive cable from Power Distri-
bution Center (PDC) and ground wire from vehicle
body.
(13) Disconnect ground wire from the vehicle body-
to-engine at the right side strut tower.
(14) Disconnect heater hoses.
(15) Disconnect vacuum hose from brake booster.
(16) Disconnect coolant reserve/recovery hose.
(17) Remove accessory drive belts. Refer to Group
7, Cooling System for procedure.
(18) Remove power steering pump and reservoir
and set them aside.
(19) Hoist vehicle and remove right inner splash
shield.
(20) Drain engine oil.
(21) Remove front wheels.
(22) Remove axle shafts. Refer to Group 3, Differ-
ential and Driveline for procedure.
(23) Disconnect exhaust system from manifold.
(24) Disconnect the downstream oxygen sensor
connector.
(25) Remove lower engine torque strut.
(26) Remove structural collar. Refer to procedure
in this section.
(27) Lower vehicle and remove A/C compressor.
(28) Raise vehicle enough to allow engine dolly
and cradle, Special Tools 6135 and 6710 to be
installed under vehicle.
(29) 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. 26). Tighten mounts to cradle frame. This
will keep support posts from moving when removing
or installing engine and transmission.
(30) Install safety straps around the engine to cra-
dle (Fig. 26). Tighten straps and lock them into posi-
tion.
WARNING: Safety straps MUST be used.(31) Raise vehicle enough to see if straps are tight
enough to hold cradle assembly to engine.
(32) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle assembly.
(33) Remove the upper engine torque strut.
(34) Remove right and left engine and transaxle
mount through bolts (Fig. 24) and (Fig. 25).
(35) Raise vehicle slowly until body is approxi-
mately 15 cm (6 in.) above normal engine mounting
locations.
(36) Remove generator, lower bracket, and upper
mounting bolt.
(37) Continue raising vehicle slowly until engine/
transaxle assembly clears engine compartment. It
may be necessary to move the engine/transmission
assembly with the cradle to allow for removal around
body flanges.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine/transaxle assembly until vehicle is within 15
cm (6 in.) of engine mounting locations.
(2) Install generator, lower bracket, and adjusting
bolt.
(3) Continue lowering vehicle until engine/tran-
saxle aligns to mounting locations. Install mounting
bolts at the right and left engine/transaxle mounts
(Fig. 24) and (Fig. 25). Tighten bolts to 118 N´m (87
ft. lbs.).
(4) Install upper engine torque strut. Refer to pro-
cedure in this section.
(5) Remove safety straps from engine/transaxle
assembly. Slowly raise vehicle enough to remove the
engine dolly and cradle.
(6) Install axle shafts. Refer to Group 3, Differen-
tial and Driveline for procedure.
(7) Install structural collar. Refer to procedure in
this section tightening sequence.
Fig. 24 Right Mount Through Bolt
1 ± BOLT
2 ± RIGHT ENGINE MOUNT
3 ± ENGINE MOUNT BRACKET
9 - 26 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(8) Install lower engine torque strut. Refer to pro-
cedure in this section.
(9) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System for procedure and torque
specifications.
(10) Connect the downstream oxygen sensor.
(11) Install A/C compressor and hoses. Refer to
Group 24, Heater and Air Conditioning for procedure.
(12) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(13) Install inner splash shield.
(14) Install wheels and lower vehicle.
(15) Install power steering pump and reservoir.
Refer to Group 7, Cooling System Accessory Drive
Section for belt tension adjustment.
(16)Manual Transmission:Connect clutch cable,
reverse light electrical connector and shift linkages.
Refer to Group 6, Clutch.
(17)Automatic Transmission:Connect shifter,
kickdown linkage and cooler lines. Refer to Group 21,
Transaxle for procedures.
(18) Connect fuel line and heater hoses.
(19)
Install all ground straps. Connect engine wiring
harness. Refer to Group 8, Electrical for procedure.
(20) Install lower radiator hose, fan module, and
upper radiator hose. Refer to Group 7, Cooling Sys-
tem for procedures
(21) Fill cooling system. Refer to Group 7, Cooling
System for filling procedure.
(22) Install battery tray and battery.
(23) Install air cleaner housing assembly and con-
nect intake duct to intake manifold.(24) Connect all throttle body electrical connectors
and linkage.
(25) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(26) 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.
Fig. 25 Left Mount Through Bolt
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
Fig. 26 Positioning Engine Cradle Support Post
1 ± SAFETY STRAPS
2 ± PLACE REAR POSTS INTO LOCATING HOLES
3 ± SPECIAL TOOL 6848
4 ± SPECIAL TOOL 6710
5 ± SPECIAL TOOL 6135
6 ± SAFETY STRAPS
7 ± PLACE FRONT POST UNDER BLOCK FLANGE
PL2.0L SOHC ENGINE 9 - 27
REMOVAL AND INSTALLATION (Continued)

INSPECT CYLINDER HEAD FOR THE FOLLOWING:
NOTE:
²Check oil feed holes for blockage.
²Inspect cylinder head camshaft bearings for
wear, Refer to Cylinder Head, Inspection and Clean-
ing.
²Check camshaft bearing journals for scratches
and worn areas. If light scratches are present, they
may be removed with 400 grit sand paper. If deep
scratches are present, replace the camshaft and
check the cylinder head for damage. Replace the
cylinder head if worn or damaged. Check the lobes
for pitting and wear. If the lobes show signs of
wear, check the corresponding rocker arm roller for
wear or damage. Replace rocker arm/hydraulic lash
adjuster if worn or damaged. If lobes show signs of
pitting on the nose, flank or base circle; replace the
camshaft.
INSTALLATION
(1) Lubricate the camshaft journals with oil and
install camshaftwithoutrocker arm assemblies
installed.
(2) Install camshaft target magnet into the end of
the camshaft. Tighten mounting screw to 3.4 N´m (30
in. lbs.).
(3) Install camshaft position sensor and tighten
mounting screws to 9 N´m (80 in. lbs.).
(4) Measure camshaft end play using the following
procedure:
(a) Mount dial indicator C-3339 or equivalent, to
a stationary point on cylinder head (Fig. 46).
(b) Using a suitable tool, move camshaft to rear-
ward limits of travel.
(c) Zero the dial indicator.
(d) Move camshaft forward to limits of travel
and read dial indicator.
(e) End 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 in this section.
(6) Install cylinder head. Refer to procedure 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 in this section.
(10) Install rocker arm assemblies in correct order
as removed. Tighten the rocker arm assemblies in
sequence shown in (Fig. 47) 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 and spark plug cables.
Tighten ignition coil fasteners to 12 N´m (105 in.
lbs.).
(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. Refer to procedure
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. 48).
Fig. 46 Camshaft End Play
Fig. 47 Rocker Arm Shaft Tightening Sequence
9 - 34 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

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.
(3) Remove power steering/air conditioning drive
belt. Refer to Group 7, Cooling System Accessory
Drive for procedure.
(4) Raise vehicle.
(5) Drain cooling system. Refer to Group 7, Cooling
System.
(6) Remove exhaust pipe from manifold.
(7) Remove right front wheel.
(8) Remove right side splash shield.
(9) Remove generator belt. Refer to Group 7, Cool-
ing System Accessory Drive Belts for procedure.
(10) Remove crankshaft damper. Refer to proce-
dure in this section.
(11) Remove lower torque strut.
(12) Lower vehicle and remove upper torque strut.
(13) Remove ground strap and power steering hose
support clip from engine mount bracket.
(14) Remove power steering pump assembly and
set aside.
(15) Support engine from beneath with a suitable
jack.
(16) Remove right side engine mount to bracket
through bolt.
(17) Remove the lower engine mount bracket bolt.
Raise engine slightly and remove the upper engine
mount bracket bolts.(18) Remove engine mount bracket. This procedure
may require additional raising/lowering of engine
until bracket will clear engine components.
(19) Remove front timing belt cover.
(20) Rotate engine until timing marks are aligned.
(21) Remove timing belt and tensioner. Refer to
procedures in this section.
(22) Remove camshaft sprocket. Refer to proce-
dures in this section.
(23) Remove rear timing belt cover.
(24) Disconnect fuel line at fuel rail.
(25) Remove coolant recovery container.
(26) Remove ground wire to cylinder head.
(27) Remove upper radiator hose.
(28) Remove intake manifold. Refer to procedure
in this section.
(29) Disconnect ignition coil electrical connector.
Remove coil pack and spark plug cables from engine.
(30) Remove Crankcase Closed Ventilation (CCV)
hose from cylinder head cover.
(31) Disconnect cam sensor and coolant tempera-
ture electrical connectors.
(32) Remove heater tube to cylinder head attach-
ing fasteners.
(33) Remove heater hose from thermostat housing
connector.
(34) Remove cylinder head cover.
(35) Remove cylinder head bolts.
(36) Remove cylinder head and gasket (Fig. 55).
PL2.0L SOHC ENGINE 9 - 37
REMOVAL AND INSTALLATION (Continued)

(13) Install ignition coil and spark plug cables.
Connect coil electrical connector.
(14) Install intake manifold. Refer to procedure in
this section.
(15) Install upper radiator hose.
(16) Install ground wire to cylinder head.
(17) Install coolant recovery container.
(18) Connect fuel line to fuel rail.
(19) Install rear timing belt cover, camshaft
sprocket, and timing belt tensioner and timing belt.
Refer to procedures in this section.
(20) Install front timing belt cover.
(21) Install engine mount bracket.
(22) Position engine and install right side engine
mount to engine mount bracket bolt. Tighten bolt to
118 N´m (87 ft. lbs.). Remove jack from beneath
engine.
(23) Install power steering pump assembly.
(24) Install power steering hose support clip and
ground strap to engine mount bracket.
(25) Install upper torque strut.
(26) Raise vehicle.
(27) Install lower torque strut.
(28) Install crankshaft damper.
(29) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Belt for procedure.
(30) Install right side splash shield and front
wheel.
(31) Install exhaust pipe to exhaust manifold
flange.
(32) Lower vehicle and fill cooling system. Refer to
Group 7, Cooling System for procedure.
(33) Connect negative cable to battery.
(34) 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.
CRANKSHAFT DAMPER
REMOVAL
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(2) Raise vehicle on a hoist and remove right inner
splash shield.
(3) Remove crankshaft damper bolt. Remove
damper using the large side of Special Tool 1026 and
insert 6827-A (Fig. 61).
INSTALLATION
(1) Install crankshaft damper using M12±1.75 x
150 mm bolt, washer, thrust bearing and nut from
Special Tool 6792 (Fig. 62).
Fig. 62 Crankshaft DamperÐInstallation
1 ± M12 Ð 1.753150 MM BOLT, WASHER AND THRUST
BEARING FROM SPECIAL TOOL 6792
Fig. 60 Cylinder Head Tightening Sequence
Fig. 61 Crankshaft DamperÐRemoval
1 ± SPECIAL TOOL 6827±A INSERT
2 ± SPECIAL TOOL 1026 THREE JAW PULLER
9 - 40 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(2) Install crankshaft damper bolt. Using Special
Tool 6847 and a torque wrench, tighten bolt to 136
N´m (100 ft. lbs.) (Fig. 63).
(3) Install accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(4) Raise vehicle on hoist and install right inner
splash shield.
TIMING BELT COVERS
FRONT TIMING BELT COVER
REMOVAL
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(2) Remove crankshaft damper. Refer to procedure
in this section.
(3) Remove lower and upper torque struts. Refer to
procedure in this section.
(4) Position a jack under engine. Raise jack
enough to support engine weight.
(5) Remove right engine mount to engine mount
bracket bolt.
(6) Remove power steering pump assembly and set
aside.
(7) Remove right engine mount bracket.
(8) Remove front timing belt cover (Fig. 64).INSTALLATION
(1) Install front timing belt cover and tighten bolts
to 12 N´m (105 in. lbs.).
(2) Install front engine mount bracket.
(3) Install right side engine mount to engine
mount bracket bolt.
(4) Remove jack from under engine.
(5) Install power steering pump assembly.
(6) Install upper and lower engine torque struts.
Refer to procedure in this section.
(7) Install crankshaft damper. Refer to procedure
in this section.
(8) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.REAR TIMING BELT COVER
REMOVAL
(1) Remove front timing belt cover following proce-
dure in this section.
(2) Remove timing belt and timing belt tensioner.
Refer to procedures in this section.
(3) Hold camshaft sprocket with Special Tools
C-4687 and modified Adaptor C-4687-1 (Fig. 66),
while removing attaching bolt.
(4) Remove camshaft sprocket.
(5) Remove rear timing cover attaching bolts (Fig.
65).
(6) Remove rear timing cover (Fig. 65).
Fig. 63 Crankshaft Damper Bolt Tightening
1 ± SPECIAL TOOL 6847
2 ± CRANKSHAFT DAMPER
Fig. 64 Front Timing Belt Cover
1 ± ACCESS PLUG
2 ± BOLTS
PL2.0L SOHC ENGINE 9 - 41
REMOVAL AND INSTALLATION (Continued)