2000 DODGE NEON Service Repair Manual

(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)

(5) Remove camshaft seal by carefully using a suit-
able pry tool. Be careful not to nick or damage thecamshaft seal surface or cylinder head seal retaining
bore.
CAUTION: Do not nick shaft seal surface or seal
bore.
(6) Shaft seal lip surface must be free of varnish,
dirt or nicks. Polish with 400 grit paper, if necessary.
INSTALLATION
(1) Install camshaft seal flush with cylinder head
using Special Tool MD998306 (Fig. 80).
(2) Install rear timing belt cover.
(3) Install camshaft sprocket retaining bolt. Hold
camshaft sprocket with Special Tools C-4687 and
modified C-4687-1 (Fig. 79) and tighten bolt to 115
N´m (85 ft. lbs.).
(4) Install timing belt tensioner, timing belt, front
cover, and crankshaft damper. Refer to procedures in
this section.
OIL PAN
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Drain engine oil and remove oil filter.
(4) Remove oil filter adaptor from engine block
(Fig. 81).
(5) Remove structural collar. Refer to procedure in
this section.
(6) Remove lateral bending brace attaching bolts
(Fig. 82).
(7) Remove lateral bending brace (Fig. 82).
(8) Remove transaxle dust cover (Fig. 82).
(9) Remove oil pan bolts.
(10) Remove oil pan.
INSTALLATION
(1) Clean oil pan and all sealing surfaces.
Fig. 78 Timing Belt Tensioner AssemblyÐRemoval/
Installation
1 ± TIMING BELT TENSIONER ASSEMBLY
2 ± TENSIONER ASSEMBLY ATTACHING BOLTS
Fig. 79 Modification to Special Tool
1 ± GRIND LOCATION
2 ± 12.7 MM (1/2 IN.)
3 ± 50.8 MM (2 IN.)
Fig. 80 Camshaft Oil SealÐInstallation
1 ± SPECIAL TOOL MD 998306
PL2.0L SOHC ENGINE 9 - 47
REMOVAL AND INSTALLATION (Continued)

(2) Apply MopartSilicone Rubber Adhesive Seal-
ant at the oil pump to engine block parting line (Fig.
83).
(3) Position a new oil pan gasket onto pan.
(4) Install oil pan and tighten screws to 12 N´m
(105 in. lbs.).
(5) Install transaxle dust cover (Fig. 82).
(6) Install lateral bending brace (Fig. 82).(7) Install structural collar. Refer to procedure in
this section.
(8) Install oil filter adaptor and tighten assembly
to 80 N´m (60 ft. lbs.) (Fig. 81).
(9) Install oil filter.
(10) Lower vehicle and fill engine crankcase with
proper oil to correct level.
CRANKSHAFT OIL SEALÐFRONT
REMOVAL
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedures.
(2) Remove crankshaft damper. Refer to procedure
in this section.
(3) Remove front timing belt cover and timing belt.
Refer to procedures in this section.
(4) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 84).
(5) Remove crankshaft sprocket key from crank-
shaft (Fig. 85).
CAUTION: Do not nick shaft seal surface or seal
bore.
Fig. 81 Oil Filter Adaptor
1 ± O-RING
2 ± LOCATING ROLL PIN
3 ± OIL FILTER ADAPTER
Fig. 82 Bending Brace, Structural Collar, and Dust
Cover
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 83 Oil Pan Sealing
1 ± PLACE A 1/8 INCH BEAD OF SEALER AT THE PARTING
LINE OF THE OIL PUMP TO ENGINE BLOCK
Fig. 84 Crankshaft SprocketÐRemoval
1 ± SPECIAL TOOL 6793
2 ± SPECIAL TOOL C-4685-C2
3 ± CRANKSHAFT SPROCKET
9 - 48 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(6) Using Special Tool 6771, remove front crank-
shaft oil seal (Fig. 86). Do not damage the seal con-
tact area on the crankshaft.
INSTALLATION
(1) Position seal into opening with seal spring
towards the inside of engine. Using Special Tool
6780-1 (Fig. 87), install seal until flush with cover.
(2) Install crankshaft sprocket key (Fig. 85).
(3) Install crankshaft sprocket (Fig. 88) using Spe-
cial Tool 6792.
NOTE: Make sure the word ªfrontº on the sprocket
is facing outward.NOTE: Use of Special Tool 6792 is required to set
proper crankshaft sprocket depth for proper timing
belt tracking.
Fig. 85 Crankshaft Key
1 ± CRANKSHAFT KEY
Fig. 86 Front Crankshaft Oil SealÐRemoval
1 ± SPECIAL TOOL 6771
Fig. 87 Front Crankshaft Oil SealÐInstallation
1 ± PROTECTOR
2 ± SEAL
3 ± SPECIAL TOOL 6780±1
4 ± INSTALLER
Fig. 88 Crankshaft SprocketÐInstallation
1 ± SPECIAL TOOL 6792
PL2.0L SOHC ENGINE 9 - 49
REMOVAL AND INSTALLATION (Continued)

(4) Install timing belt and cover. Refer to proce-
dures in this section.
(5) Install crankshaft damper. Refer to procedure
in this section.
(6) Install accessory drive belts. Refer to Group 7,
Cooling System for procedure.
CRANKSHAFT OIL SEALÐREAR
REMOVAL
(1) Remove transaxle. Refer to Group 21, Tran-
saxle for procedure.
(2) Remove drive plate. Refer to procedure in this
section.
(3) Insert a 3/16 flat bladed screwdriver between
the dust lip and the metal case of the crankshaft
seal. Angle the screwdriver (Fig. 89) through the dust
lip against metal case of the seal. Pry out seal.
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
NOTE: When installing seal, no lube on seal is
needed.
(1) Place Special Tool 6926-1 on crankshaft. This is
a pilot tool with a magnetic base (Fig. 90).
(2) Position seal over pilot tool. Make sure you can
read the wordsTHIS SIDE OUTon seal (Fig. 90).
Pilot tool should remain on crankshaft during instal-
lation of seal. Ensure that the lip of the seal is facing
towards the crankcase during installation.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Drive the seal into the block using Special Tool
6926-2 and handle C-4171 (Fig. 91) until the tool bot-
toms out against the block (Fig. 92).
(4) Install drive plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten bolts to 95 N´m
(70 ft. lbs.).
(5) Install transaxle. Refer to Group 21, Transaxle
for procedure.
Fig. 89 Rear Crankshaft Oil SealÐRemoval
1 ± REAR CRANKSHAFT SEAL
2 ± ENGINE BLOCK
3 ± ENGINE BLOCK
4 ± REAR CRANKSHAFT SEAL METAL CASE
5 ± PRY IN THIS DIRECTION
6 ± CRANKSHAFT
7 ± SCREWDRIVER
8 ± REAR CRANKSHAFT SEAL DUST LIP
9 ± SCREWDRIVERFig. 90 Rear Crankshaft Seal and Special Tool
6926-1
1 ± SPECIAL TOOL 6926±1 PILOT
2 ± SEAL
9 - 50 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

DRIVE PLATE
REMOVAL
(1) Remove transaxle. Refer to Group 21, Tran-
saxle for procedure.
(2) Remove drive plate attaching bolts (Fig. 93).
(3) Remove drive plate (Fig. 93).
INSTALLATION
(1) Position drive plate on crankshaft (Fig. 93).
(2) Apply MopartLock & Seal Adhesive to drive
plate bolt threads.
(3) Install drive plate bolts and tighten to 95 N´m
(70 ft. lbs.) (Fig. 93).
(4) Install transaxle. Refer to Group 21, Transaxle
for procedure.
Fig. 91 Crankshaft Seal Special Tool 6926-2
1 ± SPECIAL TOOL 6926±1 PILOT
2 ± SEAL
3 ± SPECIAL TOOL 6926±2 INSTALLER
Fig. 92 Rear Crankshaft SealÐInstallation
1 ± SPECIAL TOOL 6926±2 INSTALLER
Fig. 93 Drive Plate
1 ± ADAPTOR PLATE
2 ± BOLT
3 ± BOLT (QTY. 8)
4 ± DRIVE PLATE
PL2.0L SOHC ENGINE 9 - 51
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)

NOTE: Do not reuse connecting rod bolts.
(18) Remove all main bearing cap and bedplate
bolts from the engine block (Fig. 96).
(19) Using a mallet tap the bedplate loose from the
engine block dowel pins.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block and bed-
plate alignment.
(20) Bedplate should be removed evenly from the
cylinder block dowel pins.
(21) Lift out crankshaft from cylinder block (Fig.
94). Be sure not to damage the main bearings or
journals when removing the crankshaft.
CRANKSHAFT MAIN BEARINGS LOCATION
The crankshaft is supported in five main bearings.
All upper bearing shells in the crankcase have oil
grooves. All lower bearing shells installed in the (bed-
plate) main bearing cap are plain. Crankshaft endplay is controlled by a flanged bearing on the number
three main bearing journal (Fig. 97).
NOTE: The upper and lower main Bearing shells
are Not interchangeable. The lower shells have a
revised tab to prevent improper installation.
CRANKSHAFT MAIN JOURNALS INSPECTION
The crankshaft journals should be checked for
excessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be
held to 0.025 mm (0.001 in.). Journal grinding should
not exceed 0.305 mm (0.012 in.) under the standard
journal diameter. DO NOT grind thrust faces of
Number 3 main bearing. DO NOT nick crank pin or
bearing fillets. After grinding, remove rough edges
from crankshaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts
used it is important that the final paper or cloth pol-
ish after any journal regrind be in the same direc-
tion as normal rotation in the engine.
Upper and lower Number 3 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 97). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
standard and the following undersized: 0.016 mm
(0.0006 in.), 0.032 mm (0.0012 in.), 0.250 mm (0.010
in.). Never install an undersize bearing that will
reduce clearance below specifications.
Fig. 95 Torque Strut Bracket
1 ± BOLTS
2 ± TORQUE STRUT BRACKET
Fig. 96 Bedplate Bolts
Fig. 97 Main Bearing Identification
1 ± OIL GROOVES
2 ± UPPER BEARINGS
3 ± LOWER BEARINGS
4 ± OIL HOLES
PL2.0L SOHC ENGINE 9 - 53
REMOVAL AND INSTALLATION (Continued)