2000 DODGE NEON torque strut

(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)

(27) Start engine and run until operating temper-
ature is reached.
(28) Ensure engine is properly positioned. Refer to
Torque Struts in this section for adjustment proce-
dure.
(29) Adjust transmission linkage, if necessary.
INTAKE MANIFOLD
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Disconnect negative cable from battery.
(2) Remove the inlet air duct from intake manifold
to throttle body.
(3) Perform fuel system pressure release procedure
before attempting any repairs.Refer to Group 14,
Fuel System for procedures.
WARNING: WRAP SHOP TOWELS AROUND FUEL
HOSE TO CATCH ANY GASOLINE SPILLAGE
(4) Disconnect fuel supply line quick connect at the
fuel tube assembly. Refer to Group 14, Fuel System
for procedures.
(5) Remove fuel rail assembly attaching screws
and remove fuel rail assembly from engine. Cover
injector holes with suitable covering.
CAUTION: Do not set fuel injectors on their tips,
damage may occur to the injectors
(6) Disconnect brake booster hose (Fig. 27) and
PCV hose (Fig. 28) from intake manifold.
(7) Disconnect Manifold Absolute Pressure (MAP)
sensor electrical connector (Fig. 29).
(8) Disconnect knock sensor electrical connector
(Fig. 30).
(9) Disconnect wiring at starter.
(10) Remove the intake manifold to lower support
bracket bolts (Fig. 31).
(11) Remove intake manifold screws and washers.
Discard the fasteners. Remove intake manifold.
INSTALLATION
Before installing manifold. Clean all mating sur-
faces. Replace all O-ring gaskets with new gaskets
(Fig. 33). All intake manifold fasteners and washers
are to be discarded andNEWfasteners and washers
are to be used.(1) Install intake manifold onto cylinder head and
tighten fasteners to 12 N´m (105 in. lbs.) in sequence
shown in (Fig. 32).
Fig. 27 Brake Booster Hose
Fig. 28 PCV Hose
9 - 28 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)

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)

CRANKSHAFT
REMOVAL
(1) Remove engine assembly. Refer to procedure in
this section.
(2) Remove structural collar from oil pan to tran-
saxle housing.
(3) Separate transaxle from engine.
(4) Remove drive plate/flywheel.
(5) Remove crankshaft rear oil seal. Refer to pro-
cedure in this section.
(6) Mount engine on a suitable repair stand.
(7) Remove crankshaft damper, timing belt, and
tensioner. Refer to procedures in this section.
(8) Remove camshaft sprocket and rear timing belt
cover. Refer to procedures in this section.
(9) Remove crankshaft sprocket. Refer to proce-
dure in this section.(10) Remove lower torque strut/air conditioning
compressor mounting bracket from engine (Fig. 95).
(11) Remove oil filter and adapter.
(12) Remove oil pan.
(13) Remove oil pump pick-up tube.
(14) Remove oil pump.
(15) Remove crankshaft position sensor.
(16) Using a permanent ink or paint marker, iden-
tify cylinder number on each connecting rod cap.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(17) Remove all connecting rod bolts and caps.
Care should be taken not to damage the fracture rod
and cap surfaces.
Fig. 94 Crankshaft and Components
1 ± OIL PASSAGE O-RING
2 ± SEAL
3 ± UPPER BEARING (GROOVED)
4 ± THRUST BEARINGS
5 ± BOLT
6 ± O-RING
7 ± NIPPLE8 ± OIL FILTER ADAPTER
9 ± CRANKSHAFT POSITION SENSOR (CPS)
10 ± MAIN BEARING CAP/BED PLATE ASSEMBLY
11 ± CONNECTING ROD BEARINGS
12 ± PISTON AND CONNECTING ROD ASSEMBLY
13 ± SEAL
9 - 52 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)