Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Dodge Neon 1997.1999.2000.2004 Approved Dodge Neon 1997 EPL_9
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PL ENGINE 9-1
ENGINE
CONTENTS
page page
2.0L DOHC ENGINE . . . . . . . . . . . . . . . . . . . . . 52 ENGINE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 7
2.0L SOHC ENGINE . . . . . . . . . . . . . . . . . . . . . 12 STANDARD SERVICE PROCEDURES . . . . . . . . . 1
STANDARD SERVICE PROCEDURES
INDEX
page page
GENERAL INFORMATION FORM-IN-PLACE GASKETS . . . . . . . . . . . . . . .. 1
CHECKING ENGINE OIL LEVEL . . . . . . . . ..... 5 HONING CYLINDER BORES . . . . . . . . . . . . . .. 3
CRANKSHAFT SPROCKET BOLT ACCESS HYDROSTATIC LOCKED ENGINE . . . . . . . . . .. 5
PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MEASURING MAIN BEARING AND
ENGINE CORE PLUGS . . . . . . . . . . . . . . . . . . . 2 CONNECTING ROD BEARING
ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . . . . 5 CLEARANCES . . . . . . . . . . . . . . . . . . . . . . .. 3
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . 2 REPAIR OF DAMAGED OR WORN THREADS .. 5
GENERAL INFORMATION MOPAR GASKET MAKER
Mopar Gasket Maker is an anaerobic type gasket
FORM-IN-PLACE GASKETS material. The material cures in the absence of air
There are numerous places where form-in-place when squeezed between two metallic surfaces. It will
gaskets are used on the engine. Care must be taken not cure if left in the uncovered tube. The anaerobic
when applying form-in-place gaskets to assure material is for use between two machined surfaces.
obtaining the desired results. Do not use form-in- Do not use on flexible metal flanges.
place gasket material unless specified. Bead size, MOPAR TORQUE CURE GASKET MAKER
continuity, and location are of great importance. Too Mopar Torque Cure Gasket Maker is a unique
thin a bead can result in leakage while too much can anaerobic type gasket material to be used ONLY
result in spill-over which can break off and obstruct between the bedplate and engine block. The material
fluid feed lines. A continuous bead of the proper cures in the absence of air when torqued between
width is essential to obtain a leak-free gasket. two metallic surfaces. It will not cure if left in the
There are numerous types of form-in-place gasket uncovered tube. This anaerobic material is specially
materials that are used in the engine area. Mopar made to seal the area between the bedplate and cyl-
Silicone Rubber Adhesive Sealant and Mopar Gasket inder block without disturbing the bearing clearance
Maker gasket materials, each have different proper- or alignment of these components.
ties and can not be used in place of the other. GASKET DISASSEMBLY
MOPAR SILICONE RUBBER ADHESIVE Parts assembled with form-in-place gaskets may be
SEALANT disassembled without unusual effort. In some
Mopar Silicone Rubber Adhesive Sealant or equiv- instances, it may be necessary to lightly tap the part
alent, normally black in color, is available in three with a mallet or other suitable tool to break the seal
ounce tubes. Moisture in the air causes the Mopar between the mating surfaces. A flat gasket scraper
Silicone Rubber Adhesive Sealant material to cure. may also be lightly tapped into the joint but care
This material is normally used on flexible metal must be taken not to damage the mating surfaces.
flanges. It has a shelf life of one year and will not SURFACE PREPARATION
properly cure if over age. Always inspect the package Scrape clean or wire brush all gasket surfaces
for the expiration date before use. removing all loose material. Inspect stamped parts to
CUPDRIFT
BLOCK
PLUG
CYLINDER WITH PLUG
SECOND WITH HAMMER
FIRST REMOVEPLIERS
STRIKE HERE
9-2 ENGINE PL
GENERAL INFORMATION (Continued)
assure gasket rails are flat. Flatten rails with a ham-
mer on a heavy steel plate if required. Gasket sur-
faces must be free of oil and dirt. Make sure old
gasket material is removed from blind attaching
holes.
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
Mopar Gasket Maker material should be applied
sparingly 1 mm(0.040 inch.) diameter or less of seal-
ant to one gasket surface. Be certain the material
surrounds each mounting hole. Excess material can
easily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location. Fig. 1 Core Hole Plug Removal
The Mopar Silicone Rubber Adhesive Sealant gas-
ket material or equivalent should be applied in a con- least 0.5 mm (0.020 inch.) inside the lead in chamfer
tinuous bead approximately 3 mm (0.120 inch) in (Fig. 1).
diameter. All mounting holes must be circled. For It is in not necessary to wait for curing of the seal-
corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 inch.) ant. The cooling system can be refilled and the vehi-
drop is placed in the center of the gasket contact cle placed in service immediately.
area. Uncured sealant may be removed with a shop
towel. Components should be torqued in place while
ENGINE PERFORMANCE
the sealant is still wet to the touch (within 10 min- If a loss of performance is noticed, ignition timing
utes). The usage of a locating dowel is recommended should be checked. timing belt or chain may have
during assembly to prevent smearing material off the skipped one or two teeth. Camshaft and crankshaft
location. timing should also be checked. Refer to Group 9,
Engine Timing belt or chain installation.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG To provide best vehicle performance and lowest
An Access plug is located in the right inner fender vehicle emissions, it is most important that the
shield. Remove the plug and insert the proper size tune-up be done accurately. Use the specifications
socket, extension and ratchet, when crankshaft rota- listed on the Vehicle Emission Control Information
tion is necessary. label found in the engine compartment.
(1) Test cranking amperage draw. See Starting
ENGINE CORE PLUGS Motor Cranking Amperage Draw Electrical Section of
this manual.
REMOVAL (2) Check intake manifold for vacuum leaks.
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup PERFORM CYLINDER COMPRESSION TEST
plug (Fig. 1). With the cup plug rotated, grasp firmly (1) Check engine oil level and add oil if necessary.
with pliers or other suitable tool and remove plug (2) Drive the vehicle until engine reaches normal
(Fig. 1). operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
CAUTION: Do not drive cup plug into the casting laws, and accelerate through the gears several times
as restricted cooling can result and cause serious briskly.
engine problems. (3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
INSTALLATION inder number of spark plug for future reference.
Thoroughly remove all rust and clean inside of cup (4) Disconnect coil wire from distributor and
plug hole in cylinder block or head. Be sure to secure to good ground to prevent a spark from start-
remove old sealer. Lightly coat inside of cup plug hole ing a fire (Conventional Ignition System). For Direct
with sealer. Make certain the new plug is cleaned of Ignition System DIS disconnect the coil connector.
all oil or grease. Using proper drive plug, drive plug (5) Be sure throttle blade is fully open during the
into hole so that the sharp edge of the plug is at compression check.
CROSS-HATCH
PATTERN
PL ENGINE 9-3
GENERAL INFORMATION (Continued)
(6) Insert compression gage adaptor into the #1 tory surface. Inspect cylinder walls after each 20
spark plug hole in cylinder head. Crank engine until strokes, using a light honing oil. Do not use engine
maximum pressure is reached on gage. Record this or transmission oil, mineral spirits or kerosene.
pressure as #1 cylinder pressure. (3) Honing should be done by moving the hone up
(7) Repeat the previous step for all remaining cyl- and down fast enough to get a cross-hatch pattern.
inders. When hone marks intersect at 50-60 degrees, the
(8) Compression should not be less than (689kPa) cross hatch angle is most satisfactory for proper seat-
100 psi and not vary more than 25 percent from cyl- ing of rings (Fig. 2).
inder to cylinder.
(9) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(10) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary
and adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(1) Test resistance of spark plug cables. Refer to
Group 8, Electrical Ignition System Secondary Cir-
cuit Inspection.
(2) Test coil output voltage, primary and second- Fig. 2 Cylinder Bore Cross-Hatch Pattern
ary resistance. Replace parts as necessary. Refer to
(4) A controlled hone motor speed between
Group 8, Electrical Ignition System.
200-300 RPM is necessary to obtain the proper cross-
(3) Check fuel pump pressure at idle and different
hatch angle. The number of up and down strokes per
RPM ranges. Refer to Group 14, Fuel System for
minute can be regulated to get the desired 50-60
Specifications.
degree angle. Faster up and down strokes increase
(4) The air filter elements should be replaced as
the cross-hatch angle.
specified in Group 0, Lubrication and Maintenance,.
(5) After honing, it is necessary that the block be
(5) Inspect crankcase ventilation system as out
cleaned again to remove all traces of abrasive.
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls CAUTION: Ensure all abrasives are removed from
for service procedures. engine parts after honing. It is recommended that a
(6) Inspect and adjust accessory belt drives refer- solution of soap and hot water be used with a
ring to Group 7, Cooling System, Accessory Drive brush and the parts then thoroughly dried. The bore
Belts for proper adjustments. can be considered clean when it can be wiped
(7) Road test vehicle as a final test. clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
HONING CYLINDER BORES
(1) Used carefully, the cylinder bore resizing hone
C-823 equipped with 220 grit stones, is the best tool MEASURING MAIN BEARING AND CONNECTING
for this job. In addition to deglazing, it will reduce ROD BEARING CLEARANCES
taper and out-of-round as well as removing light PLASTIGAGE METHOD
scuffing, scoring or scratches. Usually a few strokes Engine crankshaft bearing clearances can be deter-
will clean up a bore and maintain the required lim- mined by use of Plastigage or equivalent. The follow-
its. ing is the recommended procedure for the use of
(2) Deglazing of the cylinder walls may be done Plastigage:
using a cylinder surfacing hone, Tool C-3501,
equipped with 280 grit stones, if the cylinder bore is
straight and round. 20-60 strokes depending on the
bore condition, will be sufficient to provide a satisfac-
PLASTIGAGE
9-4 ENGINE PL
GENERAL INFORMATION (Continued)
Fig. 3 Plastigage Placed in Lower Shell Fig. 4 Clearance Measurement
NOTE: The total clearance of the main bearings ALTERNATIVE METHOD
can only be determined by removing the weight of The weight of the crankshaft can be supported by a
the crankshaft. This can be accomplished by either jack under the counterweight adjacent to the bearing
of two methods: being checked.
PLASTIGAGE PROCEDURE
PREFERRED METHOD (1) Remove oil film from surface to be checked.
Shimming the bearings adjacent to the bearing to Plastigage is soluble in oil.
be checked in order to remove the clearance between (2) Place a piece of Plastigage across the entire
upper bearing shell and the crankshaft. This can be width of the bearing shell in the cap approximately
accomplished by placing a minimum of 0.254 mm 6.35 mm (1/4 in.) off center and away from the oil
(0.010 in.) shim (e. g. cardboard, matchbook cover, holes (Fig. 3). (In addition, suspected areas can be
etc.) between the bearing shell and the bearing cap checked by placing the Plastigage in the suspected
on the adjacent bearings and tightening bolts to area). Torque the bearing cap bolts of the bearing
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