2000 DODGE NEON Service Repair Manual

INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block. Install O-ring
into recess in the block (Fig. 98).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
CAUTION: Do Not get oil on the bedplate mating
surface. It will affect the sealer ability to seal the
bedplate to cylinder block.
(3) Oil the bearings and journals and install
crankshaft in cylinder block.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
(4) Apply 1.5±2.0 mm (0.059±0.078 in.) bead of
MopartBed Plate Sealant to cylinder block as shown
in (Fig. 99).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing the bolts oil threads with
clean engine oil, wipe off any excess oil.
(7) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block (Fig. 100).(8) Install main bearing bedplate to engine block
bolts (1±10) and torque each bolt to 81 N´m (60 ft.
lbs.) in sequence shown in (Fig. 100).
(9) Install main bearing bedplate to engine block
bolts (11±20), with baffle studs in positions 12, 13
and 16 and torque each bolt to 34 N´m (25 ft. lbs.) in
sequence shown in (Fig. 100).
(10) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
(11) If crankshaft end play is to be checked, refer
to service procedures in this section.
(12) Install connecting rod bearings and caps.
Install new connecting rod bolts and tighten to 27
N´m (20 ft. lbs.) plus 1/4 turn.
(13) Install oil pump and crankshaft front oil seal.
(14) Install oil pick-up tube and oil pan. Refer to
procedure in the section.
(15) Install oil filter adapter and filter.
(16) Install lower torque strut/air conditioning
compressor mounting bracket to engine (Fig. 95).
Fig. 98 Installing Main Bearing Upper Shell
1 ± LUBRICATION GROOVES
2 ± O-RING
3 ± OIL HOLES
Fig. 99 Main Bearing Caps/Bedplate Sealing
Fig. 100 Main Bearing Caps/Bedplate Torque
Sequence
9 - 54 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(17) Install rear timing belt cover and camshaft
sprocket.
(18) Install crankshaft sprocket, timing belt ten-
sioner, timing belt, and cover.
(19) Install front engine mount bracket.
(20) Remove engine from repair stand and position
on Special Tools 6135 and 6710 Engine Dolly and
Cradle. Install safety straps around the engine to
cradle and tighten and lock them into position.
(21) Install crankshaft rear oil seal. Refer to proce-
dure in this section.
(22) Install drive plate/flywheel. Apply Mopart
Lock & Seal Adhesive to bolt threads and tighten to
95 N´m (70 ft. lbs.).
(23) Install transaxle to engine.
(24) Install structural collar. Refer to procedure in
this section.
(25) Install engine assembly. Refer to procedure in
this section.
(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.
OIL FILTER ADAPTER
REMOVE AND INSTALL
Ensure O-ring is in the groove on adapter. Align
roll pin into engine block and tighten assembly to 80
N´m (60 ft. lbs.) (Fig. 101).
OIL FILTER
REMOVE AND INSTALL
CAUTION: When servicing the oil filter (Fig. 102),
avoid deforming the filter. Use an appropriate oil fil-
ter removing tool. Position filter wrench strap close
the seam at the base of the filter. The oil filter seam
that joins the can to the base, is reinforced by the
base plate.
(1) Turn filter counterclockwise to remove.
(2) Clean and check the filter mounting surface.
The surface must be smooth, flat and free of debris
or old pieces of rubber.
(3) To install, lubricate new filter gasket. Screw fil-
ter on until gasket contacts base. Tighten to 21 N´m
(15 ft. lbs.).
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove crankshaft damper, timing belt, and
tensioner. Refer to procedures in this section.
(3) Remove camshaft sprocket and rear timing belt
cover. Refer to procedures in this section.
(4) Remove oil pan. Refer to procedure in this sec-
tion.
(5) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 103).
(6) Remove oil pick-up tube.
(7) Remove oil pump (Fig. 104) and front crank-
shaft seal.
Fig. 101 Engine Oil Filter Adapter to Engine Block
1 ± O-RING
2 ± LOCATING ROLL PIN
3 ± OIL FILTER ADAPTER
Fig. 102 Engine Oil Filter
1 ± OIL FILTER
2 ± DRAIN PLUG
PL2.0L SOHC ENGINE 9 - 55
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.
(2) Apply MopartGasket Maker to oil pump as
shown in (Fig. 105). Install oil ring into oil pump
body discharge passage.
(3) Prime oil pump before installation.
(4) Align oil pump rotor flats with flats on crank-
shaft as you install the oil pump to the block.
NOTE: Front crankshaft seal MUST be out of pump
to align, or damage may result.
(5) Torque all oil pump attaching bolts to 28 N´m
(250 in. lbs.).
(6) Install new front crankshaft seal using Special
Tool 6780 (Fig. 106).
(7) Install crankshaft sprocket, using Special Tool
6792 (Fig. 107).
Fig. 104 Oil Pump and Tube
1 ± O-RING
2 ± OIL FILTER ADAPTER
3 ± OIL PAN GASKET
4 ± OIL PAN
5 ± OIL PICK-UP TUBE
6 ± DRAIN PLUG7 ± O-RING
8 ± OIL PUMP BODY
9 ± FILTER
10 ± O-RING
11 ± NIPPLE
Fig. 103 Crankshaft SprocketÐRemoval
1 ± SPECIAL TOOL 6793
2 ± SPECIAL TOOL C-4685-C2
3 ± CRANKSHAFT SPROCKET
9 - 56 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(8) Install oil pick-up tube and oil pan.
(9) Install rear timing belt cover and camshaft
sprocket.
(10) Install timing belt tensioner, timing belt, and
front timing belt cover.
(11) Install crankshaft damper.
(12) Fill engine crankcase with proper oil to cor-
rect level.
(13) Connect negative cable to battery.
PISTON AND CONNECTING ROD
REMOVAL
(1) Remove cylinder head and oil pan. Refer to pro-
cedures in this section.
(2) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block.Be sure to keep tops of pistons
covered during this operation. Mark piston with
matching cylinder number (Fig. 108).
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(3) Using a permanent ink marker or scribe tool
mark the cylinder number on the side of the rod and
cap (Fig. 109) for identification.
Fig. 105 Oil Pump Sealing
1 ± APPLY GASKET MAKER TO OIL PUMP BODY FLANGE
2 ± O-RING
Fig. 106 Front Crankshaft SealÐInstallation
1 ± PROTECTOR
2 ± SEAL
3 ± SPECIAL TOOL 6780±1
4 ± INSTALLER
Fig. 107 Crankshaft SprocketÐInstallation
1 ± SPECIAL TOOL 6792
2 ± TIGHTEN NUT TO INSTALL
Fig. 108 Piston Markings
1 ± WEIGHT DESIGNATION AND DIRECTIONAL ARROW WILL
BE IMPRINTED IN THIS AREA
PL2.0L SOHC ENGINE 9 - 57
REMOVAL AND INSTALLATION (Continued)

(4) Pistons will have a stamping in the approxi-
mate location shown in (Fig. 108). These stamps will
be either a directional arrow or a weight identifica-
tion for the assembly. L is for light and H is for
heavy. These assemblies should all be the same
weight class. Service piston assemblies are marked
with a S and can be used with either L or H produc-
tion assemblies. The weight designation stamps
should face toward the timing belt side of the engine.
(5) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(6) Remove connecting rod cap bolts.Do not use
old bolts if reinstalling connecting rod.
(7) To protect crankshaft journal and fractured rod
surfaces, install Special Tool 8189, connecting rod
guides onto connecting rod (Fig. 110). Carefully push
each piston and rod assembly out of cylinder bore.
CAUTION: Care must be taken not to damage the
fractured rod and cap joint surfaces, as engine
damage many occur.
(8) Remove Special Tool 8189, connecting rod
guides and re-install bearing cap on the mating rod.
NOTE: Piston and rods are serviced as an assem-
bly.
PISTON RINGÐREMOVAL
(1) The identification mark on face of upper and
intermediate piston rings must point toward piston
crown.
(2) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 111).
(3) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston.
(4) Clean ring grooves of any carbon deposits.
PISTON RINGSÐINSTALLATION
(1) Install rings with manufacturers identification
mark facing up, to the top of the piston (Fig. 112).CAUTION: Install piston rings in the following
order:
a. Oil ring expander.
b. Upper oil ring side rail.
c. Lower oil ring side rail.
d. No. 2 Intermediate piston ring.
e. No. 1 Upper piston ring.
f. Install the side rail by placing one end between
the piston ring groove and the expander. Hold end
firmly and press down the portion to be installed
until side rail is in position.Do not use a piston
ring expander (Fig. 113).
(2) Install upper side rail first and then the lower
side rail.
(3) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 112).
(4) Position piston ring end gaps as shown in (Fig.
114).
Fig. 109 Identify Connecting Rod to Cylinder
Fig. 110 Connecting Rod GuidesÐTypical
1 ± SPECIAL TOOL 8189 CONNECTING ROD GUIDES
Fig. 111 Piston RingsÐRemoving and Installing
9 - 58 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

(5) Position oil ring expander gap at least 45É from
the side rail gaps butnoton the piston pin center or
on the thrust direction. Staggering ring gap is impor-
tant for oil control.
PISTON AND RODÐINSTALLATION
(1) Before installing pistons and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 114).
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston(Fig. 115).Be sure position of rings does not
change during this operation.
(4) The weight stamp designation L or H will be in
the front half of the piston should face toward the
front of the engine (Fig. 108).
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Lubri-
cate connecting rod journal with clean engine oil.
(6) Position upper bearing half and install Special
Tool 8189, connecting rod guides onto connecting rod
(Fig. 110).
(7) Insert rod and piston assembly into cylinder
bore and carefully guide rod over the crankshaft jour-
nal.
(8) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(9) Remove Special Tool 8189, connecting rod
guides.
Fig. 112 Piston Ring Installation
1 ± NO. 1 PISTON RING
2 ± NO. 2 PISTON RING
3 ± SIDE RAIL
4 ± OIL RING
5 ± SPACER EXPANDER
Fig. 113 Installing Side Rail
1 ± SIDE RAIL END
Fig. 114 Piston Ring End Gap Position
1 ± GAP OF LOWER SIDE RAIL
2 ± NO. 1 RING GAP
3 ± GAP OF UPPER SIDE RAIL
4 ± NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 115 Installing Piston
PL2.0L SOHC ENGINE 9 - 59
REMOVAL AND INSTALLATION (Continued)

(10) Install connecting rod lower bearing half and
cap. InstallNewbolts and tighten to 27 N´m (20 ft.
lbs.) plus 1/4 turn.
(11) Install cylinder head and oil pan. Refer to pro-
cedures in this section.
DISASSEMBLY AND ASSEMBLY
OIL PUMP
(1) To remove the relief valve, proceed as follows:
(2) Remove the threaded plug and gasket from the
oil pump (Fig. 116).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 116) or serious damage
may occur.
(3) Remove spring and relief valve (Fig. 116).
(4) Remove oil pump cover screws, and lift off
cover.
(5) Remove pump rotors.
(6) Wash all parts in a suitable solvent and inspect
carefully for damage or wear (Fig. 117).
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED
REMOVAL
(1) With cylinder head removed, compress valve
springs using Special Tool C-3422-B with Adaptor
6526.(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
VALVE INSPECTION
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) Measure valve stems for wear. Measure stem
about 60 mm beneath the valve lock grooves.
(3) If valve stems are worn more than 0.05 mm
(0.002 in.), replace valve.
VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 118). Replace guides if they are not within
specification. For specifications, refer to Engine Spec-
ifications in this section.
(3) Check valve guide height (Fig. 119).
TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspec-
tion, reconditioning or replacement, valve springs
should be tested Special Tool C-647. As an example,
the compression length of the spring to be tested is
33.34 mm (1-5/16 in.). Turn tool table until surface is
in line with the 33.34 mm (1-5/16 in.) mark on the
threaded stud and the zero mark on the front. Place
spring over stud on the table and lift compressing
lever to set tone device (Fig. 120). Pull on torque
Fig. 116 Oil Pressure Relief Valve
1 ± RETAINER CAP
2 ± GASKET
3 ± OIL PUMP BODY
4 ± RELIEF VALVE
5 ± SPRING
Fig. 117 Oil Pump
1 ± OIL PUMP BODY
2 ± OIL PUMP COVER
3 ± OUTER ROTOR
4 ± INNER ROTOR
9 - 60 2.0L SOHC ENGINEPL
REMOVAL AND INSTALLATION (Continued)

wrench until ping is heard. Take reading on torque
wrench at this instant. Multiply this reading by two.
This will give the spring load at test length. Frac-
tional measurements are indicated on the table for
finer adjustments. Discard the springs that do not
meet specifications. The following specifications apply
to both intake and exhaust valve springs:
²Valve Closed Nominal TensionÐ70 lbs. @ 39.8
mm (1.57 in.)
²Valve Closed Nominal TensionÐ160 lbs. @ 32.6
mm (1.28 in.)
(2) Verify springs are not distorted with a steel
square and surface plate, check springs from both
ends. If the spring is more than 1.5 mm (1/16 in.) out
of square, install a new spring.
REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 degree angle.
(2) Inspect the remaining margin after the valves
are refaced (Fig. 121). Intake valves with less than
0.95 mm (1/32 in.) margin and exhaust valves with
less than 1.05 mm (3/64 in.) margin should be dis-
carded.
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained. For specifications, refer to Engine Specifi-
cations in this section.
(4) Measure the concentricity of valve seat and
valve guide using a valve seat runout dial indicator.
Total runout should not exceed 0.051 mm (0.002 in.)
(total indicator reading).
(5) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
Fig. 118 Checking Wear on Valve GuideÐTypical
1±TOP
2 ± MIDDLE
3 ± BOTTOM
4 ± CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
Fig. 119 Valve Guide Height
1 ± VALVE GUIDE
2 ± 13.25 - 13.75 MM (0.521-0.541 in.)
3 ± SPRING SEAT
Fig. 120 Valve Spring Testing
1 ± TORQUE WRENCH
2 ± VALVE SPRING TESTER
Fig. 121 Intake and Exhaust Valve Refacing
1 ± VALVE FACE
2 ± VALVE MARGIN
PL2.0L SOHC ENGINE 9 - 61
DISASSEMBLY AND ASSEMBLY (Continued)