2000 DODGE NEON height

nuts are torqued to half specification. Repeat the
tightening sequence, this time, to full specified
torque of 135 N´m (100 ft. lbs.).
(8) Lower the vehicle to ground level.
(9) Set the rear toe on the vehicle to the required
specification if necessary. Refer to WHEEL ALIGN-
MENT in this service manual group.
STABILIZER BAR (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove both rear wheel and tire assemblies
from the vehicle.
(3) Remove the nut from the end of each rear sta-
bilizer bar link bolt (Fig. 16). Pull the bolt out
through the top of the link and remove the link from
each end of the stabilizer bar.
(4) Remove the two bolts securing each of the two
cushion retainers to the frame rails (Fig. 1), then
remove the cushion retainers, cushions and stabilizer
bar from the vehicle as an assembly.
(5) Pull the cushion retainers off the cushions.
(6) The cushions can be removed from the bar by
utilizing the pre-formed slit in each cushion and peel-
ing it off the bar.
INSTALLATION
(1) Install the cushions on the stabilizer bar by
opening the slit in the cushion and wrapping the
cushion around the bar. When installed properly, the
slit in the cushion should face in the same direction
as the ends of the stabilizer bar, or toward the front
of the car once the bar is installed. The flat side of
each cushion should face upward.
(2) Install the retainers on the cushions, matching
the contour of each retainer with its cushion.
(3) Install the stabilizer bar, cushions and retain-
ers on the car as an assembly. The dipped area in the
center of the bar must face down to clear the well in
the luggage compartment.
(4) Install two bolts in each cushion retainer and
secure the stabilizer bar to the frame of the vehicle
(Fig. 1). Do not completely install the bolts at this
time.
(5) Reinstall each stabilizer bar link (Fig. 1):
²Place the link center sleeve and bushings
between the eye in the end of the stabilizer bar and
the link mounting bracket on the strut.
²Start the stabilizer bar link bolt with bushing
from the top, down through the stabilizer bar, inner
link bushings and sleeve, and strut link mounting
bracket.
²Install a lower bushing, then the nut. Do not
tighten the nut at this time.
(6) Install both tire and wheel assemblies on the
vehicle. Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Repeat the tightening sequence, this
time, to full specified torque of 135 N´m (100 ft. lbs.).
(7) Lower the vehicle to ground level or curb
height.
(8) Tighten the rear stabilizer bar cushion retainer
bolts to a torque of 34 N´m (300 in. lbs.).
(9) Tighten the stabilizer bar link nuts to a torque
of 23 N´m (200 in. lbs.).
(10) Set the rear toe on the vehicle to the required
specification if necessary. Refer to WHEEL ALIGN-
MENT in this service manual group.
DISASSEMBLY AND ASSEMBLY
STRUT ASSEMBLY (REAR)
The strut assembly must be removed from the
vehicle for it to be disassembled and assembled.
Refer to REMOVAL AND INSTALLATION in this
section for the required procedure.
For the disassembly and assembly of the strut
assembly, use strut spring compressor, Pentastar Ser-
vice Equipment (PSE) tool W-7200, or the equivalent,
to compress the coil spring. Follow the manufactur-
er's instructions closely.
Fig. 16 Stabilizer Bar Link
1 ± BRAKE HOSE BRACKET SCREW
2 ± STABILIZER BAR LINK
3 ± NUT
4 ± STRUT ASSEMBLY
PLSUSPENSION 2 - 47
REMOVAL AND INSTALLATION (Continued)

(5) Place the gauge (From A) over the end of the
brake tube. Adjust the tube height in the tool's jaws
until the end of the tube contacts the recessed notch
in the gauge that matches the tubing size. Squeeze
the handles of the flaring tool, locking the tubing in
place. Remove the gauge.
(6) Place the 3/16 inch plug gauge (A) down into
the end of the tube. Tighten the flaring handle, push-
ing the gauge into the tube until the gauge contacts
the vertical posts of the tool.
(7) Release the flaring handle and remove the plug
gauge from the partially flared tube.
(8) Tighten the flaring handle down once more
until the tools flaring tip has firmly seated the tube
to the vertical posts, thus completing the flare.
CAUTION: When inspecting the flare, make sure no
tubing nygal coating has been involved in the flare.
(9) Remove the flared tube from the flaring tool
and inspect the flare to make sure it is uniform.
BRAKE ROTOR MACHINING
NOTE: Refacing the rotor is not required each time
the brake pads are replaced, only when the need is
foreseen.
Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action.
If the rotor surface is deeply scored or warped, or
there is a complaint of brake roughness or brake
pedal pulsation, the rotor should be refaced using a
hub-mounted on-car brake lathe (Fig. 33), or
replaced.The use of a hub-mounted on-car brake lathe is
highly recommended to eliminate the possibility of
excessive runout. It trues the brake rotor to the vehi-
cle's hub and bearing.
NOTE: All rotors have markings for minimum allow-
able thickness cast on an un-machined surface of
the rotor (Fig. 34).
Minimum allowable thickness is the minimum
thickness which the brake rotor machined surface
may be cut to.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Before installation, verify the brake rotor face and
the hub adapters are free of any chips, rust, or con-
tamination.
When mounting and using the brake lathe, strict
attention to the brake lathe manufacturer's operating
instructions is required.
Machine both sides of the brake rotor at the same
time. Cutting both sides at the same time minimizes
the possibility of a tapered or uneven cut.
SPECIFICATIONS AND LIMITS
When refacing a rotor, the required TIR (Total
Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the oper-
ation of rotor turning equipment is required.
Fig. 33 On-Car Brake Lathe
1 ± ON-CAR BRAKE LATHE
Fig. 34 Minimum Brake Rotor Thickness Markings
(Typical)
1 ± ROTOR MINIMUM THICKNESS MARKING
2 ± ROTOR
PLBRAKES 5 - 21
SERVICE PROCEDURES (Continued)

HEADLAMP ALIGNMENT
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
HEADLAMP ALIGNMENT....................2
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION........2ADJUSTMENTS
HEADLAMP ADJUSTMENT USING
ALIGNMENT SCREEN....................2
DESCRIPTION AND OPERATION
HEADLAMP ALIGNMENT
Headlamps can be aligned using the screen method
provided in this section. This method will require the
vehicle to be parked on a flat, level surface with a
minimum of 15 meters of working room in front of a
flat, level perpendicular wall or aiming.
Each headlamp has a focal point circle molded on
the lens directly in front of each headlamp bulb.
These focal point circles are used to set up lines on a
wall, or aiming board for visually aiming the head-
lamps.
The driving (high) beam location does not require
adjustment. It will be correct when the passing (low)
beam headlamps are aimed correctly.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify that the headlamp leveling switch is in
the ª0º position.
(4) Verify proper tire inflation.
(5) Clean the headlamp lenses.
(6) Verify that the luggage area is not heavily
loaded.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ADJUSTMENTS
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position the vehicle on a level surface 10
meters in front of a level, flat wall or aiming board.
(2) Tape a vertical line on the wall extending 1
meter up from the floor, making sure this line is even
with the centerline of the vehicle (Fig. 1).
(3) Measure the cross-car distance between the
two headlamp focal point circles (1174mm). Transfer
half of this distance (587mm) to the left of the vehicle
centerline and tape another vertical line up from the
floor 1 meter (Fig. 1). Repeat for the right side of the
centerline.
(4) Measure the distance from the floor to the focal
point circle on the headlamp lens (635mm, but may
vary due to variations in tire size and vehicle suspen-
sion height). Transfer this measurement to the wall
and tape a horizontal line extending approximately 1
meter beyond each vertical focal point line (Fig. 1).
(5) Use these lines for left and right adjustment
reference.
HEADLAMP ADJUSTMENT
Horizontal Adjustment
The horizontal position of the passing (low) beam
pattern is adjusted by turning the T-15 Torx screw.
Located through the slot in the upper-crossmember
between the two attaching straps of the headlamp.
Vertical Adjustment
The vertical position of the passing (low) beam pat-
tern is adjusted by turning the Phillips screw on top
of the headlamp leveling motor. Located between the
headlamp housing and the upper-crossmember, just
inboard of the fender.
Adjust the passing (low) beam headlamp pat-
terns to the locations shown in the chart pro-
vided (Fig. 1).
8L - 2 LAMPSPL

(10) Install connecting rod lower bearing half and
cap. InstallNewbolts and tighten to 27 N´m (20 ft.
lbs.) plus 1/4 turn.
(11) Install cylinder head and oil pan. Refer to pro-
cedures in this section.
DISASSEMBLY AND ASSEMBLY
OIL PUMP
(1) To remove the relief valve, proceed as follows:
(2) Remove the threaded plug and gasket from the
oil pump (Fig. 116).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 116) or serious damage
may occur.
(3) Remove spring and relief valve (Fig. 116).
(4) Remove oil pump cover screws, and lift off
cover.
(5) Remove pump rotors.
(6) Wash all parts in a suitable solvent and inspect
carefully for damage or wear (Fig. 117).
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED
REMOVAL
(1) With cylinder head removed, compress valve
springs using Special Tool C-3422-B with Adaptor
6526.(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
VALVE INSPECTION
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) Measure valve stems for wear. Measure stem
about 60 mm beneath the valve lock grooves.
(3) If valve stems are worn more than 0.05 mm
(0.002 in.), replace valve.
VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 118). Replace guides if they are not within
specification. For specifications, refer to Engine Spec-
ifications in this section.
(3) Check valve guide height (Fig. 119).
TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspec-
tion, reconditioning or replacement, valve springs
should be tested Special Tool C-647. As an example,
the compression length of the spring to be tested is
33.34 mm (1-5/16 in.). Turn tool table until surface is
in line with the 33.34 mm (1-5/16 in.) mark on the
threaded stud and the zero mark on the front. Place
spring over stud on the table and lift compressing
lever to set tone device (Fig. 120). Pull on torque
Fig. 116 Oil Pressure Relief Valve
1 ± RETAINER CAP
2 ± GASKET
3 ± OIL PUMP BODY
4 ± RELIEF VALVE
5 ± SPRING
Fig. 117 Oil Pump
1 ± OIL PUMP BODY
2 ± OIL PUMP COVER
3 ± OUTER ROTOR
4 ± INNER ROTOR
9 - 60 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

wrench until ping is heard. Take reading on torque
wrench at this instant. Multiply this reading by two.
This will give the spring load at test length. Frac-
tional measurements are indicated on the table for
finer adjustments. Discard the springs that do not
meet specifications. The following specifications apply
to both intake and exhaust valve springs:
²Valve Closed Nominal TensionÐ70 lbs. @ 39.8
mm (1.57 in.)
²Valve Closed Nominal TensionÐ160 lbs. @ 32.6
mm (1.28 in.)
(2) Verify springs are not distorted with a steel
square and surface plate, check springs from both
ends. If the spring is more than 1.5 mm (1/16 in.) out
of square, install a new spring.
REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 degree angle.
(2) Inspect the remaining margin after the valves
are refaced (Fig. 121). Intake valves with less than
0.95 mm (1/32 in.) margin and exhaust valves with
less than 1.05 mm (3/64 in.) margin should be dis-
carded.
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained. For specifications, refer to Engine Specifi-
cations in this section.
(4) Measure the concentricity of valve seat and
valve guide using a valve seat runout dial indicator.
Total runout should not exceed 0.051 mm (0.002 in.)
(total indicator reading).
(5) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
Fig. 118 Checking Wear on Valve GuideÐTypical
1±TOP
2 ± MIDDLE
3 ± BOTTOM
4 ± CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
Fig. 119 Valve Guide Height
1 ± VALVE GUIDE
2 ± 13.25 - 13.75 MM (0.521-0.541 in.)
3 ± SPRING SEAT
Fig. 120 Valve Spring Testing
1 ± TORQUE WRENCH
2 ± VALVE SPRING TESTER
Fig. 121 Intake and Exhaust Valve Refacing
1 ± VALVE FACE
2 ± VALVE MARGIN
PL2.0L SOHC ENGINE 9 - 61
DISASSEMBLY AND ASSEMBLY (Continued)

then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of the valve face, lower valve seat
with a 15 degrees stone. If the blue is transferred to
the bottom edge of valve face raise valve seat with a
65 degrees stone.
(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±1.25 mm
(0.030±0.049 in.) (Fig. 122).
(8) Check valve tip to spring seat dimensions A
after grinding the valve seats or faces. Grind valve
tip until within specifications. Measure from valve
tip to spring seat when installed in the head (mea-
surement A) (Fig. 123). For specifications, refer to
Engine Specifications in this section. 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. 124). 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.
CAUTION: When depressing the valve spring
retainers with valve spring compressor the locks
can become dislocated. Check to make sure both
locks are in their correct location after removing
tool.
(4) Check the valve spring installed height after
refacing the valve and seat (measurment B) (Fig.
123). Make sure measurements are taken from top of
spring seat to the bottom surface of spring retainer.
If height is greater than 40.18 mm (1.58 in.), install
Fig. 122 Valve Seat Refacing
Fig. 123 Spring Installed Height and Valve Tip to
Spring Seat Dimensions
1 ± GARTER SPRING
2 ± VALVE SPRING SEAT
3 ± CYLINDER HEAD SURFACE
Fig. 124 Valve Stem Oil Seal Tool
1 ± VALVE SEAL TOOL
2 ± VALVE STEM
9 - 62 2.0L SOHC ENGINEPL
DISASSEMBLY AND ASSEMBLY (Continued)

a 0.762 mm (0.030 in.) spacer under the valve spring
seat to bring spring height back within specification.
(5) Install rocker arm shafts as previously
described in this section.
(6) Checking dry lash. Dry lash is the amount of
clearance that exists between the base circle of an
installed cam and the rocker arm roller when the
adjuster is drained of oil and completely collapsed.
Specified dry lash is 1.17 mm (0.046 in.) for intake
and 1.28 mm (0.050 in.) for exhaust. After performing
dry lash check, refill adjuster with oil and allow 10
minutes for adjuster(s) to bleed down before rotating
cam.
CLEANING AND INSPECTION
INTAKE MANIFOLD
CLEAN AND INSPECT
Check for:
²Inspect manifold for cracks or distortions.
²Check for torn or missing O-rings at the mating
surface of the manifold (Fig. 125).
EXHAUST MANIFOLD
CLEAN AND INSPECT
(1) Discard gasket and clean all gasket surfaces of
manifolds and cylinder head.
(2) Test manifold gasket surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (.006 in. per foot) of manifold length.
(3) Inspect manifolds for cracks or distortion.
Replace manifold if necessary.
CYLINDER HEAD AND CAMSHAFT JOURNALS
CLEANING
Remove all gasket material from cylinder head. Be
careful not to gouge or scratch the aluminum head
sealing surface. Clean all engine oil passages.
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Neveruse the following to clean aluminum gasket
surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 126)
NOTE: Multi-Layer Steel (MLS) head gaskets
require a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
²Solvent or a commercially available gasket
remover
²Plastic or wood scraper (Fig. 126)
²Drill motor with 3M RolocyBristle Disc (white
or yellow) (Fig. 126)
CAUTION: Excessive pressure or high RPM can
damage the sealing surfaces. The mild (white, 120
grit) bristle disc is recommended. If necessary, the
medium (yellow, 80 grit) bristle disc may be used
on cast iron surfaces with care.
Fig. 125 Intake Manifold O-Rings
1 ± INTAKE MANIFOLD O-RING GASKETS
Fig. 126 Proper Tool Usage For Surface Preparation
1 ± ABRASIVE PAD
2 ± 3M ROLOCYBRISTLE DISC
3 ± PLASTIC/WOOD SCRAPER
PL2.0L SOHC ENGINE 9 - 63
DISASSEMBLY AND ASSEMBLY (Continued)

DESCRIPTION SPECIFICATION
No. 3 41.928±41.947 mm
(1.650±1.651 in.)
No. 4 42.328±42.374 mm
(1.666±1.668 in.)
No. 5 42.728±42.747 mm
(1.682±1.6829 in.)
Bearing ClearanceÐ
Diametrical0.053±0.093 mm
(0.0027±0.003 in.)
Bearing Clearance (Max.
allowable)0.12 mm
(0.0047 in.)
End Play 0.05±0.39 mm
(0.002±0.015 in.)
Lift (Zero Lash)
Intake 7.2 mm
(0.283 in.)
Exhaust 7.03 mm
(0.277 in.)
Exhaust Valve Timing*
Closes (ATDC) 5.4É
Opens (BBDC) 43.7É
Duration 229.1É
Intake Valve Timing*
Closes (ABDC) 41.1É
Opens (ATDC) 13.9É
Duration 207.2É
Valve Overlap 84.8É
*All readings in crankshaft degrees, at 0.5 mm (0.019
in.) of valve lift.
Cylinder Head
Material Cast Aluminum
Gasket Thickness
(Compressed)1.15 mm
(0.045 in.)
Valve Seat
Angle 45É
Seat DiameterÐIntake 33 mm
(1.299 in.)
Seat DiameterÐExhaust 28 mm
(1.102 in.)
Runout (Max.) 0.05 mm
(0.002 in.)
Valve Seat WidthÐIntake
and Exhaust0.9±1.3 mm
(0.035±0.051 in.)DESCRIPTION SPECIFICATION
Service LimitÐIntake 2.0 mm
(0.079 in.)
Service LimitÐExhaust 2.5 mm
(0.098 in.)
Valve Guide
Diameter I. D. 5.975±6.000 mm
(0.235±0.236 in.)
Guide Bore Diameter
(Std.)11.0±11.02 mm
(0.4330±0.4338 in.)
Guide Height (spring seat
to guide tip)13.25±13.75 mm
(0.521±0.541 in.)
Valves
Face Angle Intake and
Exhaust45±45.5É
Head DiameterÐIntake 32.12±33.37 mm
(1.303±1.313 in.)
Head DiameterÐExhaust 28.57±28.83 mm
(1.124±1.135 in.)
Valve Margin
Intake 1.15±1.48 mm
(0.0452±0.0583 in.)
Service Limit 0.95 mm
(1/32 in.)
Exhaust 1.475±1.805 mm
(0.058±0.071 in.)
Service Limit 1.05 mm
(3/64 in.)
Valve Length (Overall)
Intake 114.69±115.19 mm
(4.515±4.535 in.)
Exhaust 116.94±117.44 mm
(4.603±4.623 in.)
Valve Stem Tip Height
Intake 45.01±46.07 mm
(1.77±1.81 in.)
Exhaust 43.51±44.57 mm
(1.71±1.75 in.)
Valve Stem Diameter
Intake 5.934±5.952 mm
(0.2337±0.2344 in.)
9 - 70 2.0L SOHC ENGINEPL
SPECIFICATIONS (Continued)