2000 DODGE NEON checking oil

ENGINE
TABLE OF CONTENTS
page page
STANDARD SERVICE PROCEDURES........... 1
ENGINE DIAGNOSIS........................ 82.0L SOHC ENGINE....................... 15
STANDARD SERVICE PROCEDURES
TABLE OF CONTENTS
page page
GENERAL INFORMATION
FORM-IN-PLACE GASKETS & SEALERS........1
ENGINE GASKET SURFACE PREPARATION.....2
CRANKSHAFT DAMPER BOLT ACCESS PLUG . . . 2
ENGINE CORE PLUGS.....................2
ENGINE PERFORMANCE...................3HONING CYLINDER BORES.................3
MEASURING WITH PLASTIGAGE.............4
REPAIR OF DAMAGED OR WORN THREADS....5
HYDROSTATIC LOCKED ENGINE.............5
CHECKING ENGINE OIL LEVEL..............6
ENGINE OIL SERVICE......................7
GENERAL INFORMATION
FORM-IN-PLACE GASKETS & SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Alwaysinspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANT
MopartBed Plate Sealant is a unique (green-in-
color) anaerobic type gasket material that is specially
made to seal the area between the bedplate and cyl-
inder block without disturbing the bearing clearance
or alignment of these components. The material
cures slowly in the absence of air when torqued
between two metallic surfaces, and will rapidly cure
when heat is applied.
PLENGINE 9 - 1

will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20±60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Inspect cyl-
inder walls after each 20 strokes, using a light
honing oil.Do not use engine or transmission oil,
mineral spirits or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 50-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 4).
(4) A controlled hone motor speed between
200±300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50±60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.MEASURING WITH PLASTIGAGE
PLASTIGAGE METHOD
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
NOTE: The total clearance of the main bearings can
only be determined by removing the weight of the
crankshaft. This can be accomplished by either of
two methods:
PREFERRED METHOD
Shim the bearings adjacent to the bearing to be
checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14-20 N´m (10-15 ft. lbs.). The number of main bear-
ing will vary from engine to engine.
ENGINE WITH 5 MAIN BEARINGS
²When checking #1 main bearing shim #2 main
bearing.
²When checking #2 main bearing shim #1 & 3
main bearing.
²When checking #3 main bearing shim #2 & 4
main bearing.
²When checking #4 main bearing shim #3 & 5
main bearing.
²When checking #5 main bearing shim #4 main
bearing.
ENGINE WITH 4 MAIN BEARING
²When checking #1 main bearing shim # 2 main
bearing.
Fig. 4 Cylinder Bore Cross-Hatch Pattern
1 ± CROSS-HATCH PATTERN
Fig. 5 Plastigage Placed in Lower Shell
1 ± PLASTIGAGE
9 - 4 ENGINEPL
GENERAL INFORMATION (Continued)

²When checking #2 main bearing shim #1 & #3
main bearing.
²When checking #3 main bearing shim #2 & #4
main bearing.
²When checking #4 main bearing shim #3 main
bearing.
NOTE: REMOVE ALL SHIMS BEFORE REASSEM-
BLING ENGINE
ALTERNATIVE METHOD
The weight of the crankshaft can be supported by a
jack under the counterweight adjacent to the bearing
being checked.
PLASTIGAGE PROCEDURE
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 5). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(3) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 6) with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Refer to Engine Specifications.Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be
determined by use of Plastigage or equivalent. Thefollowing is the recommended procedure for the use
of Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(3) Place a piece of Plastigage across the entire
width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 in.) off center and away from
the oil hole (Fig. 5). In addition, suspect areas can be
checked by placing plastigage in that area.
(4) Assemble the rod cap with Plastigage in place.
Tighten the rod cap to the specified torque.Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
(5) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 6) with the scale pro-
vided on the package. Locate the band closest to the
same width. This band indicates the amount of oil
clearance. Differences in readings between the ends
indicate the amount of taper present. Record all
readings taken. Refer to Engine Specifications.Plas-
tigage generally is accompanied by two scales.
One scale is in inches, the other is a metric
scale. If the bearing clearance exceeds wear
limit specification, replace the bearing.
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (including aluminum
head spark plug threads) can be repaired. Essen-
tially, this repair consists of drilling out worn or
damaged threads, tapping the hole with a special
Heli-Coil Tap, (or equivalent) and installing an insert
into the tapped hole. This brings the hole back to its
original thread size.
CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
Fig. 6 Clearance Measurement
PLENGINE 9 - 5
GENERAL INFORMATION (Continued)

any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.).
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Fill engine with specified amount of approved
oil and install new oil filter.
(11) Connect negative battery cable.
(12) Start engine and check for any leaks.
CHECKING ENGINE OIL LEVEL
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading. Remove dipstick (Fig. 7) and observe oil
level. Add oil only when the level is at or below the
ADD mark (Fig. 8).
Fig. 7 Dipstick and Engine Oil Fill Locations
1 ± ENGINE OIL FILL
2 ± ENGINE COOLANT RECOVERY CONTAINER3 ± ENGINE OIL DIPSTICK
4 ± COOLING SYSTEM PRESSURE CAP
Fig. 8 Oil Level
1 ± ENGINE OIL LEVEL DIPSTICK
9 - 6 ENGINEPL
GENERAL INFORMATION (Continued)

2.0L SOHC ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION..................15
ENGINE COMPONENTS...................15
ENGINE LUBRICATION SYSTEM.............17
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE..........18
SERVICE PROCEDURES
CYLINDER BORE AND PISTON SIZING........18
FITTING PISTON RINGS...................19
FITTING CONNECTING RODS...............19
FITTING CRANKSHAFT BEARINGS...........19
CRANKSHAFT END PLAY..................20
REMOVAL AND INSTALLATION
TORQUE STRUTS........................20
ENGINE MOUNTÐLEFT...................21
ENGINE MOUNTÐRIGHT..................23
ENGINE MOUNT BRACKETÐRIGHT..........24
STRUCTURAL COLLAR....................25
ENGINE ASSEMBLY.......................25
INTAKE MANIFOLD.......................28
EXHAUST MANIFOLD.....................30
CYLINDER HEAD COVER..................31
SPARK PLUG TUBE SEALS.................32
SPARK PLUG TUBE.......................33
CAMSHAFT.............................33
ROCKER ARM/HYDRAULIC LASH ADJUSTER . . . 34
VALVE SEALS AND SPRINGSÐIN VEHICLE....36
CYLINDER HEAD.........................37
CRANKSHAFT DAMPER...................40
TIMING BELT COVERS....................41TIMING BELT............................43
TIMING BELT TENSIONER..................46
CAMSHAFT OIL SEAL.....................46
OILPAN................................47
CRANKSHAFT OIL SEALÐFRONT............48
CRANKSHAFT OIL SEALÐREAR.............50
DRIVE PLATE...........................51
CRANKSHAFT...........................52
OIL FILTER ADAPTER.....................55
OILFILTER .............................55
OIL PUMP..............................55
PISTON AND CONNECTING ROD............57
DISASSEMBLY AND ASSEMBLY
OIL PUMP..............................60
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED............................60
CLEANING AND INSPECTION
INTAKE MANIFOLD.......................63
EXHAUST MANIFOLD.....................63
CYLINDER HEAD AND CAMSHAFT
JOURNALS............................63
OIL PUMP..............................64
CYLINDER BLOCK AND BORE..............65
ADJUSTMENTS
ENGINE TORQUE STRUT ADJUSTMENT......66
SPECIFICATIONS
2.0L SOHC ENGINE.......................68
TORQUE...............................71
SPECIAL TOOLS
2.0L SOHC ENGINE.......................72
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
The engine identification number is located on the
left rear of the cylinder block bedplate (Fig. 1).
ENGINE COMPONENTS
CYLINDER BLOCK AND BEDPLATE ASSEMBLY
A partial open deck is used for cooling and weight
reduction with water pump molded into the block.
Nominal wall thickness is 4 mm. The bedplate incor-
porates main bearing caps. The rear oil seal retainer
is integral with the block.
Fig. 1 Engine Identification 2.0L
1 ± ENGINE IDENTIFICATION LOCATION
PL2.0L SOHC ENGINE 9 - 15

der head. The rocker shafts route oil to the rocker
arms/hydraulic lash adjuster assemblies.
SPLASH LUBRICATION
Oil returning to the pan from pressurized compo-
nents supplies lubrication to the valve stems. Cylin-
der bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
(1) Remove oil pressure switch and install gauge
assembly C-3292 with adaptor.
(2) Run engine until thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not per-
form the 3000 RPM test in the next step.
(3) Oil Pressure:Curb Idle25 kPa (4 psi) mini-
mum3000 RPM170-550 kPa (25-80 psi).
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
SERVICE PROCEDURES
CYLINDER BORE AND PISTON SIZING
The cylinder walls should be checked for out-of-
round and taper with recommended tool C-119 or
equivalent (Fig. 3). The cylinder bore out-of-roundand cylinder bore taper must within service limits.
Refer to Engine Specifications in this section. If the
cylinder walls are badly scuffed or scored, the cylin-
der block should be rebored and honed, and new pis-
tons and rings fitted. Whatever type of boring
equipment is used, boring and honing operations
should be closely coordinated with the fitting of pis-
tons and rings in order to maintain specified clear-
ances.Refer to Honing Cylinder Bores in the
Standard Service Procedures for procedures.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 3). Top measurement should be
10 mm (3/8 inch) down and bottom measurement
should be 10 mm (3/8 inch.) up from bottom of bore.
Refer to Engine Specifications in this section for cyl-
inder block specifications.
SIZING PISTONS
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin about 17.5 mm (11/16 inch) from the bot-
tom of the skirt as shown in (Fig. 4). Cylinder bores
should be measured halfway down the cylinder bore
and transverse to the engine crankshaft center line
shown in (Fig. 3). Correct piston to bore clearance
must be established in order to assure quiet and eco-
nomical operation. Refer to Engine Specifications in
this section for cylinder block and piston specifica-
tions.
DaimlerChrysler engines use pistons designed spe-
cifically for each engine model. Clearance and sizing
locations vary with respect to engine model.
Fig. 2 Engine Lubrication SystemÐ SOHC
Fig. 3 Checking Cylinder Bore Size
9 - 18 2.0L SOHC ENGINEPL
DESCRIPTION AND OPERATION (Continued)

(2) Apply MopartGasket Sealant (aerosol can) to
both sides of the new cylinder head gasket.
(3) Position a new cylinder head gasket on the
locating dowels.
(4) Position crankshaft sprocket to TDC, then
rotate crankshaft until mark is three teeth before
TDC (Fig. 59). This will ensure that no piston-to-
valve contact occurs upon installation of cylinder
head in the event of camshaft rotation.
(5) Position the cylinder head onto the cylinder
block. Make sure the cylinder head seats fully over
the locating dowels.
(6) Before installing cylinder head bolts, the
threads should be oiled with engine oil. The 4 shorter
bolts 164 mm (6.45 in.), are to be installed in posi-
tions 7, 8, 9, and 10 (Fig. 60).
(7) Tighten the cylinder head bolts in the sequence
shown in (Fig. 60). Using the 4 step torque method,
tighten according to the following values:²First All to 34 N´m (25 ft. lbs.)
²Second All to 68 N´m (50 ft. lbs.)
²Third All to 68 N´m (50 ft. lbs.)
²Fourth Turn an additional 1/4 Turn.Do not use
a torque wrench for this step.
(8) Install cylinder head cover.
(9) Install heater hose to thermostat housing con-
nector.
(10) Install heater tube to cylinder head attaching
fasteners.
(11) Connect cam sensor and coolant temperature
electrical connectors.
(12) Connect Crankcase Closed Ventilation (CCV)
hose to cylinder head cover.
Fig. 56 Checking Cylinder Head Flatness
1 ± FEELER GAUGE
2 ± STRAIGHT EDGE
Fig. 57 Checking Bolts for Stretching (Necking)
1 ± STRETCHED BOLT
2 ± THREADS ARE NOT STRAIGHT ON LINE
3 ± THREADS ARE STRAIGHT ON LINE
4 ± UNSTRETCHED BOLT
Fig. 58 Proper Tool Usage for Surface Preparation
1 ± ABRASIVE PAD
2 ± 3M ROLOCYBRISTLE DISC
3 ± PLASTIC/WOOD SCRAPER
Fig. 59 Crankshaft Sprocket Position
1 ± TDC MARK
PL2.0L SOHC ENGINE 9 - 39
REMOVAL AND INSTALLATION (Continued)

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)