2000 DODGE NEON Service Repair Manual

CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove bolt attaching the wire harness heat
shield to the exhaust manifold support bracket (Fed-
eral and LEV) (Fig. 34), or to the exhaust manifold
(ULEV).
(4) Remove exhaust manifold support bracket
(Federal and LEV) (Fig. 35).
(5) Remove fasteners attaching exhaust system
flex joint to exhaust manifold flange. Move exhaust
system rearward to clear flange studs.
(6) ULEV equippedÐremove the support bracket
from cylinder block to exhaust manifold (Fig. 36).
(7) Lower vehicle.
(8) Disconnect CCV hose from rear of cylinder
head cover.
(9) Disconnect oxygen sensor connector and har-
ness clip.
(10) Remove heat shield attaching bolts (Fig. 37).
(11) Remove upper heat shield for access to mani-
fold bolts.
(12) Remove exhaust manifold bolts.
(13) ULEV equippedÐremove cylinder head cover.
Refer to procedure in this section. Cover cylinder
head opening with a suitable covering.
(14) Remove exhaust manifold from top of vehicle,
between cylinder head and cowl.
INSTALLATION
(1) Position exhaust manifold and gasket in place.
(2) Install exhaust manifold bolts and tighten in
sequence shown in (Fig. 38) to 23 N´m (200 in. lbs.).
(3) ULEV equippedÐposition upper heat shield on
exhaust manifold. Install bolts and tighten to 23 N´m
(200 in. lbs.).
(4) Position lower and upper heat shield on
exhaust manifold. Install heat shield bolts and
tighten to 11 N´m (95 in. lbs.) (Fig. 37).
(5) Connect oxygen sensor electrical connector and
harness clip.
(6) ULEV equippedÐinstall cylinder head cover.
Refer to procedures in this section.
Fig. 33 Intake Manifold Gaskets
1 ± INTAKE MANIFOLD O-RING GASKETS
Fig. 34 Wire Harness Heat Shield BoltÐFederal &
LEV Shown, ULEV Similar
1 ± BOLT
2 ± BRACKET
3 ± HEAT SHIELD
Fig. 35 Exhaust Manifold Support BracketÐFederal
& LEV
1 ± BRACKET
2 ± BOLT (M10)
3 ± BOLT (M12)
4 ± NUT
9 - 30 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(7) Connect CCV hose on cylinder head cover port.
(8) Raise vehicle.
(9) Install new flex joint to manifold flange gasket.
(10) Attach exhaust system to manifold flange and
tighten fasteners to 28 N´m (250 in. lbs.).
(11) Install exhaust manifold support bracket (Fed-
eral and LEV) (Fig. 35). Tighten M10 bolt to 54 N´m
(40 ft. lbs.), M12 bolt to 95 N´m (70 ft. lbs.), and nut
to 28 N´m (250 in. lbs.).
(12) ULEV equippedÐinstall support bracket to
cylinder block and exhaust manifold (Fig. 36). Snug
all bolts first then tighten to 54 N´m (40 ft. lbs.).
(13) Install bolt attaching wire harness heat shield
to support bracket (Federal and LEV) (Fig. 34), or
exhaust manifold (ULEV).(14) Lower vehicle.
(15) Connect negative cable to battery.
CYLINDER HEAD COVER
REMOVAL
(1) Disconnect CCV (Fig. 39) and PCV (Fig. 40)
hoses from cylinder head cover.
(2) Remove ignition coil and spark plug cables
(Fig. 41).
(3) Remove cylinder head cover bolts.
(4) Remove cylinder head cover.
INSTALLATION
(1) Clean gasket surfaces. Inspect gasket and seals
(Fig. 42). Replace as necessary. For replacement of
spark plug tube seals, refer to Spark Plug Tube Seals
in this section for procedure.
CAUTION: Do not attempt to loosen or remove baf-
fle plate attaching screws. The screws are self-tap-
ping, and in the attempt to retighten, thread damage
(stripping) will result.
Fig. 36 Exhaust Manifold Support BracketÐULEV
1 ± MANIFOLD SUPPORT BRACKET
2 ± OIL FILTER
3 ± BOLTS
Fig. 37 Exhaust Manifold Heat Shields
1 ± BOLTS
2 ± HEAT SHIELDS
Fig. 38 Exhaust Manifold Tightening Sequence
Fig. 39 CCV Hose
PL2.0L SOHC ENGINE 9 - 31
REMOVAL AND INSTALLATION (Continued)

(2) Install cylinder head cover and gasket. Tighten
bolts to 12 N´m (105 in. lbs.).
(3) Install ignition coil and spark plug cables (Fig.
41). Tighten ignition coil fasteners to 12 N´m (105 in.
lbs.).
(4) Connect CCV (Fig. 39) and PCV (Fig. 40) hoses.
SPARK PLUG TUBE SEALS
The spark plug tube seals are located in the cylin-
der head cover (Fig. 43). These seals are pressed into
the cylinder head cover to seal the outside perimeter
of the spark plug tubes. If these seals show signs of
hardness and/or cracking, they should be replaced.
REMOVAL
(1) Remove cylinder head. Refer to procedure in
this section.
(2) Using an appropriate tool, carefully remove
spark plug tube seals. Care should be taken not to
damage cylinder head cover sealing surfaces.
INSTALLATION
(1) Clean all sealing surfaces.
Fig. 40 PCV Valve Hose
Fig. 41 Ignition Coil and Spark Plug Cables
1 ± IGNITION COILS
2 ± SPARK PLUG CABLE
3 ± SPARK PLUG INSULATOR
Fig. 42 Cylinder Head Cover Gasket and Seals
1 ± CYLINDER HEAD COVER GASKET
2 ± SEAL
3 ± BOLT
4 ± SPARK PLUG TUBE SEALS
Fig. 43 Spark Plug Tube Seals
1 ± SPARK PLUG TUBE SEAL
2 ± CYLINDER HEAD COVER
9 - 32 2.0L SOHC ENGINEPL
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)

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)

HYDRAULIC LASH ADJUSTER NOISE
A tappet-like noise may be produced from several
items. Refer to Lash Adjuster Noise - Diagnosis in
Standard Service Procedures, in this Group.Lash
adjusters are replaced with the rocker arm as
an assembly.
VALVE SEALS AND SPRINGSÐIN VEHICLE
REMOVAL
(1) Remove rocker arm shafts assemblies. Refer to
procedure in this section.
(2) Rotate crankshaft until piston is at TDC on
compression stroke.
(3) With air hose attached to adapter tool installed
in spark plug hole, apply 90-120 psi air pressure.
(4) Using Special Tool MD-998772A with adapter
6779 (Fig. 52) compress valve springs and remove
valve locks.
(5) Remove valve spring.
(6) Remove valve stem seal by using a valve stem
seal tool (Fig. 53).
INSTALLATION
(1) Install valve seal/valve spring seat assembly.
Refer to Valve Installation procedure in this section.
(2) Using Special Tool MD-998772A compress valve
springs only enough to install locks. Correct align-
ment of tool is necessary to avoid nicking valve stems
(air pressure required), piston at TDC.
(3) Install rocker arm shaft assemblies. Refer to
procedure in this section.
(4) Install cylinder head cover. Refer to procedure
in this section.
Fig. 51 Rocker Arm Shaft Tightening Sequence
Fig. 52 Valve SpringÐRemoving and Installing
1 ± VALVE SPRING COMPRESSOR SPECIAL TOOL MD-998772A
2 ± ADAPTER 6779
3 ± AIR HOSE
Fig. 53 Valve Stem Oil Seal Tool
1 ± VALVE SEAL TOOL
2 ± VALVE STEM
Fig. 54 Valve Spring Assembly
1 ± VALVE RETAINING LOCKS
2 ± VALVE SPRING
3 ± VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY
4 ± VALVE SPRING RETAINER
9 - 36 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)