2000 DODGE NEON check engine

CRANKSHAFT END PLAY
DIAL INDICATOR METHOD
(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 9).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front of its
travel and read the dial indicator. Refer to Engine
Specifications in this section for crankshaft specifica-
tions.
FEELER GAGE METHOD
(1) Move crankshaft all the way to the rear of its
travel using a lever inserted between a main bearing
cap and a crankshaft cheek, using care not to dam-
age any bearing surface. Donotloosen main bearing
cap.(2) Use a feeler gauge between number three
thrust bearing and machined crankshaft surface to
determine end play.
REMOVAL AND INSTALLATION
TORQUE STRUTS
UPPER TORQUE STRUT
REMOVAL
(1) Remove bolts attaching strut to shock tower
bracket and engine mount bracket (Fig. 10).
(2) Remove the upper torque strut.
INSTALLATION
(1) Position the upper torque strut into mounting
locations.
(2) Install the mounting bolts and perform the
torque strut adjustment procedure.
LOWER TORQUE STRUT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove right side splash shield.
(3) Remove bolts attaching lower strut to cross-
member and strut bracket (Fig. 10).
(4) Remove lower torque strut.
INSTALLATION
(1) Position lower torque strut into mounting loca-
tions.
(2) Install mounting bolts and perform torque
strut adjustment procedure.
(3) Install splash shield and lower vehicle
TORQUE STRUT ADJUSTMENT
The upper and lower torque struts need to be
adjusted together to assure proper engine positioning
and engine mount loading. Whenever a torque strut
bolt(s) is loosened, this procedure must be performed.
(1) Loosen the upper and lower torque strut
attaching bolt at the suspension crossmember and
shock tower bracket.
(2) The engine position may now be adjusted by
positioning a suitable floor jack on the forward edge
of the transmission bell housing (Fig. 11).
NOTE: The floor jack must be positioned as shown
in (Fig. 11) to prevent minimal upward lifting of the
engine.
Fig. 8 Connecting Rod Side Clearance
Fig. 9 Checking Crankshaft End PlayÐ Dial
Indicator
9 - 20 2.0L SOHC ENGINEPL
SERVICE PROCEDURES (Continued)

(2) Install intake manifold to lower support
bracket bolts (Fig. 31). Tighten bolts to 11 N´m (95
in. lbs.).
(3) Remove covering from fuel injector holes and
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 N´m (200 in.
lbs.).
(4) Connect PCV and brake booster hoses.
(5) Inspect quick connect fittings for damage,
replace if necessary Refer to Group 14, Fuel System
for procedure. Apply a light amount of clean engine
oil to fuel inlet tube. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(6) Connect Manifold Absolute Pressure (MAP)
Sensor wiring connector (Fig. 29).(7) Connect knock sensor connector, and wiring at
starter.
(8) Install inlet air duct to intake manifold and
throttle body. Tighten clamp to 3 N´m (30 in. lbs.).
(9) Connect negative cable to battery.
(10) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
Fig. 29 MAP Sensor
Fig. 30 Knock Sensor
1 ± KNOCK SENSOR
2 ± STARTER MOTOR
Fig. 31 Intake Manifold Lower Supports
1 ± BOLT
2 ± BRACKET
3 ± BRACKET
4 ± BOLT
Fig. 32 Intake Manifold Tightening Sequence
PL2.0L SOHC ENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)

INSPECT CYLINDER HEAD FOR THE FOLLOWING:
NOTE:
²Check oil feed holes for blockage.
²Inspect cylinder head camshaft bearings for
wear, Refer to Cylinder Head, Inspection and Clean-
ing.
²Check camshaft bearing journals for scratches
and worn areas. If light scratches are present, they
may be removed with 400 grit sand paper. If deep
scratches are present, replace the camshaft and
check the cylinder head for damage. Replace the
cylinder head if worn or damaged. Check the lobes
for pitting and wear. If the lobes show signs of
wear, check the corresponding rocker arm roller for
wear or damage. Replace rocker arm/hydraulic lash
adjuster if worn or damaged. If lobes show signs of
pitting on the nose, flank or base circle; replace the
camshaft.
INSTALLATION
(1) Lubricate the camshaft journals with oil and
install camshaftwithoutrocker arm assemblies
installed.
(2) Install camshaft target magnet into the end of
the camshaft. Tighten mounting screw to 3.4 N´m (30
in. lbs.).
(3) Install camshaft position sensor and tighten
mounting screws to 9 N´m (80 in. lbs.).
(4) Measure camshaft end play using the following
procedure:
(a) Mount dial indicator C-3339 or equivalent, to
a stationary point on cylinder head (Fig. 46).
(b) Using a suitable tool, move camshaft to rear-
ward limits of travel.
(c) Zero the dial indicator.
(d) Move camshaft forward to limits of travel
and read dial indicator.
(e) End play travel: 0.13±0.33 mm (0.005±0.013
in.).
(5) Install front camshaft seal. Camshaft must be
installed before the camshaft seal is installed. Refer
to procedure in this section.
(6) Install cylinder head. Refer to procedure in this
section.
(7) Install rear timing belt cover.
(8) Install camshaft sprocket and tighten to 115
N´m (85 ft. lbs.).
(9) Install timing belt tensioner and timing belt.
Refer to procedures in this section.
(10) Install rocker arm assemblies in correct order
as removed. Tighten the rocker arm assemblies in
sequence shown in (Fig. 47) to 28 N´m (250 in. lbs.).
(11) Install cylinder head cover and tighten fasten-
ers to 12 N´m (105 in. lbs.).(12) Install ignition coil and spark plug cables.
Tighten ignition coil fasteners to 12 N´m (105 in.
lbs.).
(13) 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.
ROCKER ARM/HYDRAULIC LASH ADJUSTER
REMOVAL
(1) Remove cylinder head cover. Refer to procedure
in this section.
(2) Identify the rocker arm shaft assemblies before
removal.
(3) Loosen the attaching fasteners. Remove rocker
arm shaft assemblies from cylinder head.
(4) Identify the rocker arms spacers and retainers
for reassembly. Disassemble the rocker arm assem-
blies by removing the attaching bolts from the shaft
(Fig. 48).
Fig. 46 Camshaft End Play
Fig. 47 Rocker Arm Shaft Tightening Sequence
9 - 34 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(5) Slide the rocker arms and spacers off the shaft.
Keep the spacers and rocker arms in the same loca-
tion for reassembly.
NOTE: Inspect the rocker arm for scoring, wear on
the roller or damage to the rocker arm (Fig. 49)
Replace if necessary. Check the location where the
rocker arms mount to the shafts for wear or dam-
age. Replace if damaged or worn. The rocker arm
shaft is hollow and is used as a lubrication oil duct.
Check oil holes for clogging with small wire, clean
as required. Lubricate the rocker arms and spacers.
Install onto shafts in their original position (Fig. 48).
INSTALLATION
CAUTION: Set crankshaft to 3 notches before TDC
before installing rocker arm shafts. Refer to Timing
Belt System and Camshaft Seal Service of this sec-
tion for procedure.
(1) Install rocker arm/hydraulic lash adjuster
assembly making sure that adjusters are at least
partially full of oil. This is indicated by little or no
plunger travel when the lash adjuster is depressed. If
there is excessive plunger travel. Place the rocker
arm assembly into clean engine oil and pump the
plunger until the lash adjuster travel is taken up. If
travel is not reduced, replace the assembly. Hydraulic
lash adjuster and rocker arm are serviced as an
assembly.(2) Install rocker arm and shaft assemblies with
NOTCH in the rocker arm shafts pointing up and
toward the timing belt side of the engine (Fig. 50).
Install the retainers in their original positions on the
exhaust and intake shafts (Fig. 48).
CAUTION: When installing the intake rocker arm
shaft assembly be sure that the plastic spacers do
not interfere with the spark plug tubes. If the spac-
ers do interfere rotate until they are at the proper
angle. To avoid damaging the spark plug tubes, do
not attempt rotating the spacers by forcing down
the shaft assembly.
(3) Tighten bolts to 28 N´m (250 in. lbs.) in
sequence shown in (Fig. 51).
(4) Install cylinder head cover. Refer to procedures
in this section.
Fig. 48 Rocker Arm Shaft Assemblies
1 ± EXHAUST ROCKER ARM ASSEMBLY
2 ± PLASTIC SHAFT SPACERS
3 ± INTAKE ROCKER ARM ASSEMBLY
4 ± ROCKER ARM SHAFT RETAINERS
Fig. 49 Rocker Arm Assemblies
1 ± EXHAUST ROCKER ARM
2 ± HYDRAULIC LASH ADJUSTERS
3 ± INTAKE ROCKER ARM
4 ± ROLLERS
Fig. 50 Rocker Arm Shaft Notches
1 ± NOTCHES FACING UP AND TOWARD THE TIMING BELT
SIDE OF THE ENGINE
PL2.0L SOHC ENGINE 9 - 35
REMOVAL AND INSTALLATION (Continued)

NOTE: Inspect camshaft bearing journals for scor-
ing. Cylinder head must be flat within 0.1 mm (0.004
inch) (Fig. 56).
INSTALLATION
EXAMINING CYLINDER HEAD BOLTS
NOTE: The cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolt(s) should be replaced (Fig. 57).
Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale, the bolt(s) should be
replaced.CLEANING CYLINDER HEAD SEALING SURFACES
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper.
Sealing surfaces could be cut or ground, resulting
in gasket leaks. Use only the cleaning methods
shown in (Fig. 58). If required, use a white (120 grit)
3M RolocYbristle disk on aluminum surfaces. A
yellow (80 grit) bristle disk can be used on cast iron
surfaces with care.
(1) Clean the cylinder head and cylinder block
sealing surfaces using a wood/plastic scraper. Apply
solvent or a commercially available gasket remover
to help soften the gasket residue. If additional clean-
ing is required, use a white (120 grit) 3M Rolocy
bristle disk and a drill motor to remove gasket resi-
due.
Fig. 55 Cylinder Head Assembly
1 ± ROCKER SHAFT RETAINING BOLT
2 ± VALVE RETAINING LOCKS
3 ± VALVE
4 ± VALVE SPRING
5 ± VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY
6 ± SPARK PLUG TUBE SEAL
7 ± CAMSHAFT
8 ± ROCKER ARM SHAFT RETAINER SPACER
9 ± GASKET10 ± SPACER
11 ± INTAKE ROCKER ARM/HYDRAULIC LASH ADJUSTER
ASSEMBLY
12 ± EXHAUST ROCKER ARM/HYDRAULIC LASH ADJUSTER
ASSEMBLY
13 ± CAMSHAFT SEAL
14 ± RETAINER SPACER
15 ± VALVE SPRING RETAINER
9 - 38 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (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)

CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE AND BELT INSTALLATION
(1) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing,
then back off to 3 notches before TDC (Fig. 73).(2) Set camshaft to TDC by aligning mark on
sprocket with the arrow on the rear of timing belt
cover (Fig. 73).
(3) Move crankshaft to 1/2 mark before TDC (Fig.
75) for belt installation.
(4) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket and then around
the camshaft sprocket.
(5) Move crankshaft sprocket to TDC to take up
belt slack.
(6) Remove the pin or 1/8º or 3 mm Allen wrench
from belt tensioner.
(7) Rotate crankshaft 2 revolutions and check the
alignment of the timing marks (Fig. 76).
(8) Install front timing belt cover.
(9) Install engine mount bracket.
Fig. 72 Timing Belt Removal
1 ± CAMSHAFT TIMING MARKS
2 ± BELT TENSIONER
3 ± CRANKSHAFT AT TDC
4 ± 1/8º OR 3mm ALLEN WRENCH
5 ± 8 mm ALLEN WRENCH
Fig. 73 Crankshaft Sprocket Timing
1 ± TDC MARK
Fig. 74 Camshaft Timing Mark
1 ± CAM SPROCKET TIMING MARK
2 ± ARROW ON REAR COVER
Fig. 75 Adjusting Crankshaft Sprocket for Timing
Belt Installation
1 ± TDC REFERENCE MARK
2 ± 1/2 NOTCH LOCATION
3 ± TDC MARK
PL2.0L SOHC ENGINE 9 - 45
REMOVAL AND INSTALLATION (Continued)