2000 DODGE NEON Service Repair Manual

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)

(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)

INSTALLATION
(1) Install rear timing cover and tighten bolts to
12 N´m (105 in. lbs.) (Fig. 65).
(2) Install camshaft sprocket. While holding
sprockets with Special Tools C-4687 and modifiedAdaptor C-4687-1, tighten attaching bolt to 101 N´m
(75 ft. lbs.).
(3) Install timing belt tensioner assembly and tim-
ing belt. Refer to procedure in this section.
(4) Install front timing belt cover following proce-
dure in this section.
Fig. 65 Rear Timing Belt Cover
1 ± BOLTS
Fig. 66 Modification to Special Tool C-4687-1
1 ± GRIND LOCATION
2 ± 12.7 MM (1/2 IN.)
3 ± 50.8 MM (2 IN.)
9 - 42 2.0L SOHC ENGINEPL
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)

(11) Inserta8mmAllen wrench into the hexagon
opening located on the front of the belt tensioner pul-
ley (Fig. 72). Rotate the pulley counterclockwise until
it contacts the stop. While holding tensioner pulley
against stop, insert a 1/8º or 3 mm diameter pin or
Allen wrench through the hole located to the left of
the hex opening (Fig. 72). While pushing pin into
hole, allow the tensioner pulley to rotate back.
Almost immediately, the pin should engage the lock-
ing hole to prevent further movement of the pulley.
(12) Remove timing belt.
CAUTION: Do not rotate the camshafts once the
timing belt has been removed or damage to valve
components may occur.
Fig. 68 Camshaft Timing Marks
1 ± CAM SPROCKET TIMING MARK
2 ± ARROW ON REAR COVER
Fig. 69 Crankshaft DamperÐRemoval
1 ± SPECIAL TOOL 6827±A INSERT
2 ± SPECIAL TOOL 1026 THREE JAW PULLER
Fig. 70 Right Engine Mount Bracket
1 ± BOLTS
2 ± ENGINE MOUNT BRACKET ASSEMBLY
Fig. 71 Timing Belt Cover
1 ± ACCESS PLUG
2 ± BOLTS
9 - 44 2.0L SOHC ENGINEPL
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)