2000 DODGE NEON steering

TIMING BELT
CHECKING BELT TIMINGÐCOVER INSTALLED
²Remove number one spark plug.
²Using a dial indicator, set number one cylinder
to TDC on the compression stroke.
²Remove the access plug from the outer timing
belt cover (Fig. 67).
²Check the timing mark on the camshaft
sprocket, it should align with the arrow on the rear
belt cover (Fig. 68).
REMOVALÐTIMING BELT
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedures.
(2) Raise vehicle on a hoist and remove right inner
splash shield.(3) Remove crankshaft damper bolt. Remove
damper using Special Tools 1026 three jaw puller
and 6827-A insert (Fig. 69).
(4) Remove lower torque strut.
(5) Lower vehicle and place a jack under engine.
(6) Remove upper torque strut.
(7) Remove right engine mount to engine mount
bracket through bolt.
(8) Remove power steering pump assembly and set
aside.
(9) Remove engine mount bracket (Fig. 70).
(10) Remove front timing belt cover (Fig. 71).
CAUTION: Align camshaft and crankshaft timing
marks before removing the timing belt by rotating
the engine with the crankshaft.
Fig. 67 Timing Belt System
1 ± CAMSHAFT SPROCKET
2 ± REAR TIMING BELT COVER
3 ± TIMING BELT TENSIONER ASSEMBLY
4 ± WATER PUMP
5 ± OIL PUMP BODY
6 ± CRANKSHAFT SPROCKET7 ± TIMING BELT
8 ± BOLT
9 ± CRANKSHAFT DAMPER
10 ± FRONT TIMING BELT COVER
11 ± ACCESS PLUG
12 ± CAMSHAFT BOLT AND WASHER
PL2.0L SOHC ENGINE 9 - 43
REMOVAL AND INSTALLATION (Continued)

(10) Install right engine mount to engine mount
bracket through bolt.
(11) Remove jack from under engine.
(12) Install upper torque strut.
(13) Install power steering pump assembly.
(14) Raise vehicle and install lower torque strut.
(15) 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 (100 ft. lbs.) (Fig. 77).
(16) Install accessory drive belts. Refer to Group 7,
Cooling System for procedures.
(17) Install right inner splash shield.
(18) Lower vehicle and 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 TENSIONER
REMOVAL
(1) Remove timing belt. Refer to procedure in this
section.
(2) Remove tensioner assembly attaching bolts
(Fig. 78).
(3) Remove tensioner assembly.
CAUTION: The timing belt tensioner is serviced as
an assembly. To prevent premature timing belt fail-
ure, DO NOT separate the tensioner pulley from
mounting bracket.
INSTALLATION
(1) Install timing belt tensioner assembly. Tighten
attaching bolts to 31 N´m (275 in. lbs.).
(2) Install timing belt. Refer to procedure in this
section.
CAMSHAFT OIL SEAL
REMOVAL
CAUTION: Do Not Rotate the camshaft or crank-
shaft when timing belt is removed damage to the
engine may occur.
(1) Remove crankshaft damper, front timing belt
cover, timing belt and tensioner assembly. Refer to
procedures in this section.
(2) Hold camshaft sprocket with Special Tools
C-4687 and modified C-4687-1 as shown in (Fig. 79),
while removing attaching bolt.
(3) Remove sprocket from camshaft.
(4) Remove rear timing belt cover.
Fig. 76 Crankshaft and Camshaft Timing
1 ± CAMSHAFT TIMING MARKS
2 ± CRANKSHAFT AT TDC
Fig. 77 Crankshaft DamperÐInstallation
1 ± M12 Ð 1.753150 MM BOLT, WASHER AND THRUST
BEARING FROM SPECIAL TOOL 6792
9 - 46 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(17) Install rear timing belt cover and camshaft
sprocket.
(18) Install crankshaft sprocket, timing belt ten-
sioner, timing belt, and cover.
(19) Install front engine mount bracket.
(20) Remove engine from repair stand and position
on Special Tools 6135 and 6710 Engine Dolly and
Cradle. Install safety straps around the engine to
cradle and tighten and lock them into position.
(21) Install crankshaft rear oil seal. Refer to proce-
dure in this section.
(22) Install drive plate/flywheel. Apply Mopart
Lock & Seal Adhesive to bolt threads and tighten to
95 N´m (70 ft. lbs.).
(23) Install transaxle to engine.
(24) Install structural collar. Refer to procedure in
this section.
(25) Install engine assembly. Refer to procedure in
this section.
(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.
OIL FILTER ADAPTER
REMOVE AND INSTALL
Ensure O-ring is in the groove on adapter. Align
roll pin into engine block and tighten assembly to 80
N´m (60 ft. lbs.) (Fig. 101).
OIL FILTER
REMOVE AND INSTALL
CAUTION: When servicing the oil filter (Fig. 102),
avoid deforming the filter. Use an appropriate oil fil-
ter removing tool. Position filter wrench strap close
the seam at the base of the filter. The oil filter seam
that joins the can to the base, is reinforced by the
base plate.
(1) Turn filter counterclockwise to remove.
(2) Clean and check the filter mounting surface.
The surface must be smooth, flat and free of debris
or old pieces of rubber.
(3) To install, lubricate new filter gasket. Screw fil-
ter on until gasket contacts base. Tighten to 21 N´m
(15 ft. lbs.).
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove crankshaft damper, timing belt, and
tensioner. Refer to procedures in this section.
(3) Remove camshaft sprocket and rear timing belt
cover. Refer to procedures in this section.
(4) Remove oil pan. Refer to procedure in this sec-
tion.
(5) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 103).
(6) Remove oil pick-up tube.
(7) Remove oil pump (Fig. 104) and front crank-
shaft seal.
Fig. 101 Engine Oil Filter Adapter to Engine Block
1 ± O-RING
2 ± LOCATING ROLL PIN
3 ± OIL FILTER ADAPTER
Fig. 102 Engine Oil Filter
1 ± OIL FILTER
2 ± DRAIN PLUG
PL2.0L SOHC ENGINE 9 - 55
REMOVAL AND INSTALLATION (Continued)

FRAMES
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
FRONT SUSPENSION......................5
REMOVAL AND INSTALLATION
FRONT SUSPENSION CROSSMEMBER........5SPECIFICATIONS
FRAME DIMENSIONS......................9
STRUCTURAL DIMENSIONS................13
TORQUE SPECIFICATIONS.................15
DESCRIPTION AND OPERATION
FRONT SUSPENSION
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 for
additional information.
REMOVAL AND INSTALLATION
FRONT SUSPENSION CROSSMEMBER
CAUTION: If the front suspension crossmember is
being replaced due to collision damage, inspect the
steering column lower coupling for damage. Refer
to STEERING COLUMN in the STEERING service
manual group for the procedure.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group in this
service manual for the correct lifting procedure.
(2) Remove both front tire and wheel assemblies
from the vehicle.
(3) Remove both stabilizer bar links from the vehi-
cle (Fig. 1). Remove each link by holding the upper
retainer/nut with a wrench and turning the link bolt.
(4) Remove the stabilizer bar cushion retainer
bolts and retainers (Fig. 1), and remove the stabilizer
bar with cushions attached from the vehicle.
(5) Remove the nut and pinch bolt clamping each
ball joint stud to the steering knuckle (Fig. 2).
Fig. 1 Stabilizer Bar
1 ± STABILIZER BAR CUSHION RETAINERS
2 ± CUSHIONS
3 ± FRONT STABILIZER BAR
4 ± STABILIZER BAR LINKS
PLFRAME AND BUMPERS 13 - 5

CAUTION: After removing the steering knuckle from
the ball joint stud, do not pull outward on the knuckle.
Pulling the steering knuckle outward at this point can
separate the inner C/V joint on the driveshaft. Refer to
FRONT DRIVESHAFTS in the DIFFERENTIAL AND
DRIVELINE group for further information.
NOTE: Use caution when separating the ball joint
stud from the steering knuckle, so the ball joint seal
does not get cut.
(6) Separate each ball joint stud from the steering
knuckle by prying down on lower control arm and up
against the ball joint boss on the steering knuckle
(Fig. 3).
(7) If the vehicle is equipped with a power steering
fluid cooler, remove the two screws securing the
cooler to the front suspension crossmember. They are
located behind the cooler and can be accessed from
above. Allow the cooler to hang out of the way.
(8) Using wire or cord, support and tie off the
power steering gear to the underbody of the vehicle,
so when the crossmember is lowered, the gear does
not fall away being held to the vehicle by only the
steering column coupler and the fluid hoses.
(9) Loosen and remove the four bolts attaching the
power steering gear to the front suspension cross-
member (Fig. 4). Remove the power steering gear
from the front suspension crossmember.
(10) Remove the bolt mounting the engine torque
strut to the right forward corner of the front suspen-
sion crossmember (Fig. 5).
NOTE: Before removing the front suspension
crossmember from the vehicle, the location of thecrossmember must be scribed on the body of the
vehicle (Fig. 9). Do this so that the crossmember
can be relocated upon reinstallation against the
body of vehicle in the same location as before
removal. If the front suspension crossmember is
not reinstalled in exactly the same location as
before removal, the preset front wheel alignment
settings (caster and camber) will be lost.
(11) Using an awl, scribe a line (Fig. 6) marking
the location of where the front suspension crossmem-
ber is mounted against the body of the vehicle.
(12) Position a transmission jack under the center
of the front suspension crossmember and raise it to
support the bottom of the crossmember.
(13) Loosen and completely remove the two front
bolts (one right and one left) attaching the front sus-
pension crossmember to the frame rails of vehicle.
The right side bolt can be viewed in the mounting
bolt figure (Fig. 5). The left side bolt is located in the
same location on the other side of the vehicle.
(14) Loosen the two rear bolts (one right and one
left) attaching the front suspension crossmember and
lower control arms to the body of the vehicle until
they release from the threaded tapping plates in the
body of the vehicle. Remove the rear bolts from the
body of the vehicle, but do not completely remove the
rear bolts because they are designed to disengage
from the body threads yet stay within the lower con-
trol arm rear isolator bushing. This allows the lower
control arm to stay in place on the crossmember. The
right side bolt can be viewed in the mounting bolt
figure (Fig. 5). The left side bolt is located in the
same location on the other side of the vehicle.
(15) Lower the front suspension crossmember.
Fig. 2 Ball Joint Bolt And Nut
1 ± NUT
2 ± BOLT
3 ± BALL JOINT
Fig. 3 Pry Bar Usage
1 ± STEERING KNUCKLE
2±PRYBAR
3 ± LOWER CONTROL ARM
4 ± BALL JOINT STUD
13 - 6 FRAME AND BUMPERSPL
REMOVAL AND INSTALLATION (Continued)

(16) Remove each lower control arm from the
crossmember by removing the front pivot bolt.
INSTALLATION
(1) Install the lower control arms on the front sus-
pension crossmember. Install the pivot bolts, but do
not completely tighten them at this time.(2) Using the transmission jack, raise the front
suspension crossmember and lower control arms
until the crossmember contacts its mounting spot
against the body and frame rails of the vehicle. As
the crossmember is raised, carefully guide the power
steering gear into mounting position.
Fig. 4 Steering Gear Mounting
1 ± OUTER TIE ROD
2 ± JAM NUT3 ± STEERING GEAR
4 ± FRONT SUSPENSION CROSSMEMBER
Fig. 5 Mounting Bolts
1 ± FRONT SUSPENSION CROSSMEMBER MOUNTING BOLTS
2 ± ENGINE TORQUE ISOLATOR STRUT MOUNTING BOLT
3 ± FRONT SUSPENSION CROSSMEMBER
Fig. 6 Marking Crossmember Location
1 ± SCRIBED LINE
2 ± FRONT SUSPENSION CROSSMEMBER
3±AWL
4 ± BODY
PLFRAME AND BUMPERS 13 - 7
REMOVAL AND INSTALLATION (Continued)

(3) Start the two rear crossmember mounting bolts
into the tapping plates mounted in the body. The
right side bolt can be viewed in the mounting bolt
figure (Fig. 5). The left side bolt is located in the
same location on the other side of the vehicle. Next,
install the two front mounting bolts attaching front
suspension crossmember to frame rails of vehicle.
Lightly tighten all four mounting bolts to a approxi-
mately 2 N´m (20 in. lbs.) to hold the front suspen-
sion crossmember in position.
NOTE: When reinstalling the front suspension
crossmember back in the vehicle, it is very impor-
tant that the crossmember be attached to the body
in exactly the same spot as when it was removed.
Otherwise, the vehicle's wheel alignment settings
(caster and camber) will be lost.
(4) Using a soft face hammer, tap the front suspen-
sion crossmember back-and-forth or side-to-side until
it is aligned with the previously scribed positioning
marks on the body of the vehicle (Fig. 6). Once the
front suspension crossmember is correctly positioned,
tighten the rear two crossmember mounting bolts to
a torque of 203 N´m (150 ft. lbs.), then tighten the
front two crossmember mounting bolts to a torque of
142 N´m (105 ft. lbs.).
(5) Tighten the lower control arm front pivot bolts
to a torque of 163 N´m (120 ft. lbs.).
(6) Attach the steering gear to the front suspen-
sion crossmember (Fig. 4). Install the four power
steering gear mounting bolts. Tighten the mounting
bolts to a torque of 61 N´m (45 ft. lbs.).
(7) Remove the wire or cord suspending the power
steering gear to the underbody.
(8) If the vehicle is equipped with a power steering
fluid cooler, install the two screws securing the cooler
to the front suspension crossmember. They are
located behind the cooler.
(9)
Install each ball joint stud into the steering
knuckle aligning the bolt hole in the knuckle boss with
the notch formed in the side of the ball joint stud.
(10) Install a new ball joint stud pinch bolt and
nut (Fig. 2). Tighten the nut to a torque of 95 N´m
(70 ft. lbs.).
(11) Fasten the engine torque strut to the right
forward corner of the front suspension crossmember
using its mounting bolt (Fig. 5). Follow the procedure
described in the ENGINE service manual group to
properly align and tighten the torque strut and it's
mounting bolts.
NOTE: Before installing the stabilizer bar, make
sure the bar is not upside-down. The stabilizer bar
must be installed with the curve on the outboard
ends of the bar facing downward to clear the con-
trol arms once fully installed (Fig. 7).(12)
First, place the stabilizer bar in position on the
front suspension crossmember. The slits in each cush-
ion must point toward the front of the vehicle and sit
directly on top of the raised beads formed into the
stamping on the crossmember. Next, install the cush-
ion retainers, matching the raised beads formed into
the cushion retainers to the grooves formed into the
cushions. Install the cushion retainer bolts, but do not
completely tighten them at this time.
(13) Install both stabilizer bar links back on vehi-
cle (Fig. 1). Start each stabilizer bar link bolt with
bushing from the bottom, through the stabilizer bar,
inner link bushings, lower control arm, and into the
upper retainer/nut and bushing. Do not fully tighten
the link assemblies at this time.
(14) Install the tire and wheel assemblies back on
vehicle. Tighten the wheel mounting nuts to 135 N´m
(100 ft. lbs.) torque.
(15) Lower the vehicle.
NOTE: It may be necessary to put the vehicle on a
platform hoist or alignment rack to gain access to
the stabilizer bar mounting bolts with the vehicle at
curb height.
(16) Tighten each stabilizer bar link by holding the
upper retainer/nut with a wrench and turning the
link bolt. Tighten each link bolt to a torque of 23
N´m (200 in. lbs.).
(17) Tighten the stabilizer bar cushion retainer
bolts to a torque of 34 N´m (300 in. lbs.).
(18) Check the front wheel alignment on the vehi-
cle. Refer to WHEEL ALIGNMENT in the SUSPEN-
SION service manual group.
Fig. 7 Downward Curve
1 ± STABILIZER BAR
2 ± LINK
3 ± DOWNWARD CURVE
4 ± CUSHION RETAINER
13 - 8 FRAME AND BUMPERSPL
REMOVAL AND INSTALLATION (Continued)

FUEL INJECTION SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
INJECTION SYSTEM......................22
MODES OF OPERATION...................22
SYSTEM DIAGNOSIS......................24
POWER DISTRIBUTION CENTER............24
POWERTRAIN CONTROL MODULE...........24
PCM GROUND...........................26
5 VOLT SUPPLYÐPCM OUTPUT.............26
8-VOLT SUPPLYÐPCM OUTPUT.............26
FUEL CORRECTION or ADAPTIVE MEMORIES . . 26
PROGRAMMABLE COMMUNICATIONS
INTERFACE (PCI) BUS...................27
AIR CONDITIONING PRESSURE
TRANSDUCERÐPCM INPUT..............27
AUTOMATIC SHUTDOWN (ASD) SENSEÐ
PCM INPUT...........................27
BATTERY VOLTAGEÐPCM INPUT............28
BRAKE SWITCHÐPCM INPUT...............28
CAMSHAFT POSITION SENSORÐPCM INPUT . . 28
CLUTCH INTERLOCK/UPSTOP SWITCH.......29
CRANKSHAFT POSITION SENSORÐPCM
INPUT................................30
ENGINE COOLANT TEMPERATURE
SENSORÐPCM INPUT...................30
FUEL LEVEL SENSORÐPCM INPUT..........31
HEATED OXYGEN SENSOR (O2 SENSOR)Ð
PCM INPUT...........................32
IGNITION CIRCUIT SENSEÐPCM INPUT......34
INLET AIR TEMPERATURE SENSORÐPCM
INPUT................................34
KNOCK SENSORÐPCM INPUT..............34
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐPCM INPUT...................35
POWER STEERING PRESSURE SWITCHÐ
PCM INPUT...........................35
SENSOR RETURNÐPCM INPUT.............35
SPEED CONTROLÐPCM INPUT.............36
SCI RECEIVEÐPCM INPUT.................36
PARK/NEUTRAL POSITION SWITCHÐPCM
INPUT................................36
THROTTLE POSITION SENSORÐPCM INPUT . . 36VEHICLE SPEED SIGNAL (VSS)ÐPCM INPUT . . 37
AIR CONDITIONING CLUTCH RELAYÐPCM
OUTPUT..............................38
AUTOMATIC SHUTDOWN RELAYÐPCM
OUTPUT..............................38
CHARGING SYSTEM INDICATOR LAMPÐPCM
OUTPUT..............................38
FUEL PUMP RELAYÐPCM OUTPUT..........38
PROPORTIONAL PURGE SOLENOIDÐPCM
OUTPUT..............................39
GENERATOR FIELDÐPCM OUTPUT..........39
IDLE AIR CONTROL MOTORÐPCM OUTPUT . . . 39
DATA LINK CONNECTOR...................40
FUEL INJECTORSÐPCM OUTPUT...........40
IGNITION COILÐPCM OUTPUT..............40
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMPÐPCM OUTPUT...................41
SPEED CONTROLÐPCM INPUT.............41
SCI RECEIVEÐPCM OUTPUT...............41
TACHOMETERÐPCM OUTPUT..............42
TORQUE CONVERTOR CLUTCH SOLENOIDÐ
PCM OUTPUT..........................42
REMOVAL AND INSTALLATION
THROTTLE BODY........................42
THROTTLE POSITION SENSOR.............43
IDLE AIR CONTROL MOTOR................43
MAP SENSOR...........................44
POWERTRAIN CONTROL MODULE (PCM).....44
UPSTREAM HEATED OXYGEN SENSOR......45
DOWNSTREAM HEATED OXYGEN SENSOR
1/2 ..................................46
AIR CLEANER BOX.......................46
AIR CLEANER ELEMENT...................47
ENGINE COOLANT TEMPERATURE SENSOR . . . 47
VEHICLE SPEED SENSOR.................47
KNOCK SENSOR.........................48
SPECIFICATIONS
VECI LABEL.............................49
TORQUE...............................49
SPECIAL TOOLS
FUEL..................................49
PLFUEL SYSTEM 14 - 21