2000 DODGE NEON timing

KNOCK SENSOR
DESCRIPTION
The knock sensor threads into the cylinder block.
OPERATION
When the knock sensor detects a knock in one of
the cylinders, it sends an input signal to the PCM. In
response, the PCM retards ignition timing for all cyl-
inders by a scheduled amount.Knock sensors contain a piezoelectric material
which constantly vibrates and sends an input voltage
(signal) to the PCM while the engine operates. As the
intensity of the crystal's vibration increases, the
knock sensor output voltage also increases.
NOTE: Over or under tightening affects knock sen-
sor performance, possibly causing improper spark
control.
IGNITION SWITCH
In the RUN position, the ignition switch connects
power from the Power Distribution Center (PDC) to a
fuse in the fuse block, back to a bus bar in the PDC.
The bus bar feeds circuits for the Powertrain Control
Module (PCM), Proportional purge solenoid, EGR
solenoid, and ABS system. The bus bar in the PDC
feeds the coil side of the radiator fan relay, A/C com-
pressor clutch relay, and the fuel pump relay. It also
feeds the Airbag Control Module (ACM)
LOCK KEY CYLINDER
DESCRIPTION
The lock cylinder is inserted in the end of the
housing opposite the ignition switch.
OPERATION
The ignition key rotates the cylinder to 5 different
detents (Fig. 9) :
²Accessory
²Off (lock)
²Unlock
²On/Run
²Start
Fig. 7 Target MagnetÐTypical
1 ± CAM MAGNET/TARGET
2 ± CAMSHAFT POSITION SENSOR
Fig. 8 Target Magnet Polarity
1 ± TARGET MAGNET
Fig. 9 Ignition Lock Cylinder Detents
PLIGNITION SYSTEM 8D - 5
DESCRIPTION AND OPERATION (Continued)

ELECTRICALLY HEATED SYSTEMS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
REAR WINDOW DEFOGGER SYSTEM.........1
REAR WINDOW DEFOGGER SWITCH.........1
DIAGNOSIS AND TESTING
GRID LINES.............................2
REAR WINDOW DEFOGGER SWITCH.........2REAR WINDOW DEFOGGER SYSTEM.........2
SERVICE PROCEDURES
GRID LINE AND TERMINAL REPAIR..........3
REMOVAL AND INSTALLATION
REAR WINDOW DEFOGGER SWITCH.........4
DESCRIPTION AND OPERATION
REAR WINDOW DEFOGGER SYSTEM
For proper operation of the Rear Window Defogger
system refer to the Owner's Manual.
The system consists of a rear glass with two verti-
cal bus bars and a series of electrically connected
grid lines fired on the inside surface (Fig. 1). A con-
trol switch and a timing circuit are combined into a
single assembly.
Circuit protection is provided by a cartridge fuse
located in the Power Distribution Center (PDC) for
the heated grid circuit, and by a fuse in the fuse
block for the control circuit.
When the switch is turned to the ON position, cur-
rent is directed to the rear defogger grid lines. The
heated grid lines heat the rear glass to clear the sur-
face of fog or frost.CAUTION: Grid lines can be damaged or scraped
off with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
REAR WINDOW DEFOGGER SWITCH
The rear window defogger switch is a control
switch and timing circuit integrated into a single
panel mounted assembly (Fig. 2). Actuating the
switch energizes the circuit which allows current to
flow through the grid lines. Upon initial actuation for
approximately eight to ten minutes, or until either
the switch or ignition is turned off. An indicating
lamp illuminates a Light Emitting Diode (LED)
inlaid in the control switch.
Fig. 1 Rear Window Defogger - Typical
1 ± REAR WINDOW DEFOGGER
Fig. 2 Rear Window Defogger Switch Location
1 ± REAR WINDOW DEFOGGER SWITCH
2 ± TRACTION CONTROL SWITCH
3 ± CIGAR LIGHTER/AUXILIARY POWER OUTLET
PLELECTRICALLY HEATED SYSTEMS 8N - 1

CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly clean all debris/rust from inside of cup
plug hole in cylinder block or head. Be sure to
remove old sealer. Lightly coat inside of cup plug hole
with MopartStud and Bearing Mount Adhesive.
Make certain the new plug is cleaned of all oil or
grease. Using a proper driver, drive plug into hole so
that the sharp edge of the plug is at least 0.5 mm
(0.020 inch.) inside the lead in chamfer (Fig. 3).
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
ENGINE PERFORMANCE
If a loss of performance is noticed, timing belt or
chain may have skipped one or two teeth. Camshaft
and crankshaft timing should be checked. Refer to
Group 9, Engine Timing belt or chain installation.
It is important that the vehicle is operating to it's
optimum performance level to maintain fuel economy
and lowest vehicle emissions. If vehicle is not operat-ing to these standards, refer to Engine Diagnosis in
this section. The following procedures can assist in
achieving the proper engine diagnosis.
(1) Test cranking amperage draw. Refer to Group
8B, Starting.
(2) Check intake manifold for vacuum leaks.
(3) Perform cylinder compression pressure test.
Refer to Engine Diagnosis in this section.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified in Group 8D, Ignition System.
Tighten to specifications.
(5) Test resistance of spark plug cables. Refer to
Group 8D, Ignition System.
(6) Test ignition coils primary and secondary resis-
tance. Replace parts as necessary. Refer to Group 8D,
Ignition System.
(7) Check fuel pump pressure at idle and different
RPM ranges. Refer to Group 14, Fuel System for
specifications.
(8) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance.
(9) Inspect crankcase ventilation system. Refer to
Group 25, Emission Control Systems.
(10) Road test vehicle as a final test.HONING CYLINDER BORES
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
Fig. 2 Access Plug
1 ± CRANKSHAFT BOLT ACCESS PLUG
2 ± RIGHT MOUNT BOLT ACCESS PLUG
3 ± FASCIA
4 ± SPLASH SHIELD
Fig. 3 Core Hole Plug Removal
1 ± CYLINDER BLOCK
2 ± REMOVE PLUG WITH PLIERS
3 ± STRIKE HERE WITH HAMMER
4 ± DRIFT PUNCH
5 ± CUP PLUG
PLENGINE 9 - 3
GENERAL INFORMATION (Continued)

ENGINE DIAGNOSISÐPERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. Refer to Group 8A,
Battery.
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. Refer to
Group 8B, Starting.
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
Refer to Group 8D, Ignition System.
5. Incorrect spark plug gap. 5. Set gap. Refer to Group 8D,
Ignition System.
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. Refer to Group 14, Fuel
System.
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. Refer to
Group 14, Fuel System.
2. Incorrect fuel mixture. 2. Refer to Group 14, Fuel System.
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty coil(s). 4. Test and replace as necessary.
Refer to Group 8D, Ignition System.
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. Refer to
Group 8D, Ignition System.
2. Contamination in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
Refer to Group 14, Fuel System.
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust
system.8. Install new parts, as necessary.
9. Faulty coil(s). 9. Test and replace as necessary.
Refer to Group 8D, Ignition System.
PLENGINE 9 - 11
DIAGNOSIS AND TESTING (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

CRANKSHAFT
A nodular cast iron crankshaft is used. The engine
has five main bearings. The number three main is
flanged to control thrust. The mains and connecting
rod journals have undercut fillet radiuses that are
deep rolled for added strength. To optimize bearing
loading, eight counterweights are used. Hydrody-
namic seals provide end sealing, where the crank-
shaft exits the block. Anaerobic gasket material is
used for parting line sealing. A sintered iron timing
belt sprocket is mounted on the crankshaft nose. This
sprocket transmits crankshaft movement, via timing
belt to the camshaft sprocket providing timed valve
actuation.
PISTONS
The engineDOES NOThave provision for a free
wheeling valve train. Non free wheeling valve train
means, in the event of a broken timing belt pistons
will contact the valves. The engine uses pressed-in
piston pins to attach forged powdered metal connect-
ing rods. The connecting rods are a cracked cap
design and are not repairable. Hex head cap screw
are used to provide alignment and durability in the
assembly. Pistons and connecting rods are serviced as
an assembly.
PISTON RINGS
The piston rings include a molybdenum faced top
ring for reliable compression sealing and a taper
faced intermediate ring for additional cylinder pres-
sure control. Oil Control Ring Package consist of two
steel rails and an expander spacer.
CYLINDER HEAD
The aluminum cylinder head features a Single
Over Head Camshaft (SOHC), four-valves per cylin-
der, cross flow design. The valves are arranged in
two inline banks, with the two intake per cylinder
facing toward the radiator. The exhaust valves facing
toward the dash panel. Rocker arm shafts mount
directly to the cylinder head. It incorporates powder
metal valve guides and seats. The hollow rocker arm
shafts supplies oil to the hydraulic lash adjusters,
camshaft and valve mechanisms.
CAMSHAFT
The nodular iron camshaft has five bearing jour-
nals and three cam lobes per cylinder. Provision for a
cam position sensor is provided on the camshaft at
the rear of cylinder head which also acts as thrust
plate. A hydrodynamic oil seal is used for oil control
at the front of the camshaft.
VALVES
Four valves per cylinder are actuated by roller
rocker arms/hydraulic lash adjusters assemblies
which pivot on rocker arm shafts. All valves have
chrome plated valve stems. Viton rubber valve stem
seals are integral with spring seats. Valve springs,
spring retainers, and locks are conventional design.
INTAKE MANIFOLD
The intake manifold is a molded plastic composi-
tion, attached to the cylinder head with five fasten-
ers. This long branch design enhances low and mid-
range torque.
EXHAUST MANIFOLD
The exhaust manifold is made of nodular cast iron
for strength and high temperatures. Exhaust gasses
exit the manifold into an articulated joint connection
and exhaust pipe.
COMPONENT REPLACEMENT
If any of the following parts have been changed or
replaced:
²Camshaft
²Camshaft Position Sensor
²Camshaft Position Sensor Target Magnet
²Cylinder Block
²Cylinder Head
²Water Pump
²Powertrain Control Module (PCM)
²Timing Belt and Timing Belt Tensioner
The camshaft and crankshaft timing relearn proce-
dure must be performed. Refer to the component
Removal and Installation procedure in this section.
9 - 16 2.0L SOHC ENGINEPL
DESCRIPTION AND OPERATION (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)

NOTE: Position seal with the concave side facing
the installation tool.
(2) Install seals using Special Tool MB-998306.
Only hand pressure on tool is needed to install new
seals.
(3) Install cylinder head cover. Refer to procedures
in this section.
SPARK PLUG TUBE
(1) Remove cylinder head cover. Refer to procedure
in this section.
(2) Using locking pliers remove the tube from the
cylinder head (Fig. 45). Discard old tube.
(3) Clean area around spark plug with Mopart
parts cleaner or equivalent.
(4) Apply MopartStud and Bearing Mount or
equivalent to a new tube approximately 1 mm from
theendina3mmwide area.
(5) Install sealer end of tube into the cylinder
head. Then carefully install the tube using a hard-
wood block and mallet until the tube is seated into
the bottom of the bore.
(6) Install cylinder head cover. Refer to procedure
in this section.
CAMSHAFT
NOTE: TO REMOVE CAMSHAFT THE CYLINDER
HEAD MUST BE REMOVED.
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs.Refer to Group 14,
Fuel System
(2) Remove the cylinder head cover. Refer to proce-
dure in this section.
(3) Mark rocker arm shaft assemblies so that they
are installed in their original positions.
(4) Remove rocker arm shaft bolts. Refer to proce-
dure in this section.
(5) Remove timing belt, timing belt tensioner, and
camshaft sprocket. Refer to procedures in this sec-
tion.
(6) Remove rear timing belt cover.
(7) Remove cylinder head. Refer to procedure in
this section.
(8) Remove camshaft sensor and camshaft target
magnet.
(9) Remove camshaft from the rear of cylinder
head.
Fig. 44 Spark Plug Tube Seal Installation
1 ± SPECIAL TOOL MB-998306
2 ± SPARK PLUG TUBE SEAL
Fig. 45 Spark Plug TubeÐRemoval
1 ± LOCKING PLIERS
2 ± SPARK PLUG TUBE
PL2.0L SOHC ENGINE 9 - 33
REMOVAL AND INSTALLATION (Continued)