Dodge Neon / Neon SRT-4. Manual - part 235

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.

(4) Verify that hydraulic lash adjuster swivel feet

are still in place.

(5) Tighten bolts to 28 N·m (250 in. lbs.) in

sequence shown in (Fig. 28).

(6) Install the cylinder head cover (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - INSTALLATION).

CAMSHAFT

DESCRIPTION

The camshaft is made of nodular iron with five

bearing journal surfaces and three cam lobes per cyl-
inder. Provision for a cam position sensor is provided
on the rear of the camshaft. The camshaft position
sensor bolts to the rear of the cylinder head and also
controls camshaft thrust. A hydrodynamic oil seal is
used for oil control at the front of the camshaft.

OPERATION

The camshaft is driven by the crankshaft via drive

sprockets and belt. The camshaft has precisely
machined lobes to provide accurate valve timing and
duration.

STANDARD PROCEDURE - CAMSHAFT
END-PLAY

(1) Measure camshaft end play using the following

procedure:

(a) Mount dial indicator C-3339 or equivalent, to

a stationary point on cylinder head (Fig. 29).

(b) Using a suitable tool, move camshaft to rear-

ward limits of travel.

and read dial indicator.

(e) End play travel: 0.13–0.33 mm (0.005–0.013

in.).

REMOVAL

(1) Disconnect and isolate negative battery cable.
(2) Disconnect positive battery cable. Remove the

battery (Refer to 8 - ELECTRICAL/BATTERY SYS-
TEM/BATTERY - REMOVAL).

(3) Disconnect the IAT sensor electrical connector

(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/IN-
LET AIR TEMPERATURE SENSOR - DESCRIP-
TION) .

(4) Disconnect the following:
• Air intake duct at throttle body

• Throttle cables

• TPS and IAC connectors

• Make-up air hose at air cleaner housing
(5) Remove the air cleaner housing assembly

(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER HOUSING - REMOVAL).

(6) Remove the battery tray. (Refer to 8 - ELEC-

TRICAL/BATTERY SYSTEM/TRAY - REMOVAL)

(7) Remove the front timing belt cover, timing belt,

and tensioner (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT AND SPROCKETS - REMOVAL).

(8) Remove the camshaft sprocket and rear timing

belt cover (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - REMOVAL).

(9) Remove the cylinder head cover (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - REMOVAL).

(10) Mark rocker arm shaft assemblies so that

they are installed in their original positions.

Fig. 28 Rocker Arm Shaft Tightening Sequence

Fig. 29 Camshaft End Play

9 - 34

ENGINE 2.0L SOHC

PL/SRT-4

ROCKER ARM / HYDRAULIC LASH ADJUSTER ASSEMBLY (Continued)

(11) Remove rocker arm and shaft assemblies

(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - REMOVAL).

(12) Drain cooling system below heater hose level.
(13) Disconnect the ECT sensor electrical connec-

tor.

(14) Disconnect hoses from heater supply and

return tubes.

(15) Remove heater tube support bracket bolts at

rear of cylinder head.

(16) Remove PDC attaching screws and reposition

for camshaft removal clearance.

(17) Remove camshaft sensor and camshaft target

magnet (Refer to 8 - ELECTRICAL/IGNITION CON-
TROL/CAMSHAFT

POSITION

SENSOR

REMOVAL).

(18) Carefully remove camshaft from the rear of

cylinder head. Reposition heater tubes and PDC for
camshaft clearance (Fig. 30).

(19) Remove the camshaft seal (Refer to 9 -

ENGINE/CYLINDER

HEAD/CAMSHAFT

OIL

SEAL(S) - REMOVAL).

CLEANING

Clean camshaft with a suitable solvent.

INSPECTION

(1) Inspect camshaft bearing journals for damage

and binding (Fig. 31). If journals are binding, check
the cylinder head for damage. Also check cylinder
head oil holes for clogging.

(2) Check the cam lobe and bearing surfaces for

abnormal wear and damage. Replace camshaft if
defective.

NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the rocker arms.

(3) Measure the lobe actual wear (unworn area -

wear zone = actual wear) (Fig. 31) and replace cam-

shaft if out of limit. Standard value is 0.0254 mm
(0.001 in.), wear limit is 0.254 mm (0.010 in.).

INSTALLATION

(1) Lubricate the camshaft journals with oil.
(2) Carefully install the camshaft into the cylinder

head. Reposition the PDC and heater tubes for clear-
ance (Fig. 30).

(3) Install camshaft target magnet into the end of

the camshaft. Tighten mounting screw to 3.4 N·m (30
in. lbs.).

(4) Install camshaft position sensor (Refer to 8 -

ELECTRICAL/IGNITION

CONTROL/CAMSHAFT

POSITION SENSOR - INSTALLATION).

(5) Measure camshaft end-play (Refer to 9 -

ENGINE/CYLINDER HEAD/CAMSHAFT - STAN-
DARD PROCEDURE).

NOTE: Camshaft must be installed before installa-
tion of the camshaft seal.

(6) Install camshaft seal (Refer to 9 - ENGINE/

CYLINDER

HEAD/CAMSHAFT

OIL

SEAL

INSTALLATION).

(7) Install rear timing belt cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).

(8) Install the camshaft sprocket on the camshaft.

CAUTION: DO NOT use an impact wrench (or any
other air operated tool) for tightening the camshaft
sprocket bolt. Damage to the camshaft timing pin
can result. ONLY use a hand wrench while holding
camshaft sprocket with Special Tool.

(9) Install camshaft sprocket retaining bolt. While

holding sprocket with Special Tools C-4687 and mod-

Fig. 30 Camshaft Removal

1 - POWER DISTRIBUTION CENTER (PDC)
2 - CAMSHAFT

Fig. 31 Checking Camshaft(s) for Wear

1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE

PL/SRT-4

ENGINE 2.0L SOHC

9 - 35

CAMSHAFT (Continued)

ified Adaptor C-4687-1, tighten attaching bolt to 115
N·m (85 ft. lbs.).

(10) Install

timing

belt

and

tensioner/bracket

assembly (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT AND SPROCKETS - INSTALLA-
TION).

(11) Install front timing belt cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).

(12) Install rocker arm and shaft assemblies in

correct order as removed (Refer to 9 - ENGINE/CYL-
INDER HEAD/ROCKER ARM / HYDRAULIC LASH
ADJUSTER ASSEMBLY - INSTALLATION).

(13) Install the cylinder head cover (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - INSTALLATION).

(14) Install ignition coil and spark plug cables.

Tighten ignition coil fasteners to 12 N·m (105 in.
lbs.).

(15) Install the heater tube bracket attaching bolt.
(16) Connect the heater hoses to the heater tubes.
(17) Connect the ECT electrical connector.
(18) Install the PDC attaching screws.
(19) Install the battery tray (Refer to 8 - ELEC-

TRICAL/BATTERY

SYSTEM/TRAY

INSTALLA-

TION).

(20) Install the air cleaner housing assembly

(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER HOUSING - INSTALLATION).

(21) Connect the following:
• Air intake duct at throttle body

• Throttle cables

• TPS and IAC connectors

• Make-up air hose at air cleaner housing
(22) Connect the IAT sensor.
(23) Install battery. Connect positive battery cable

(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT-
TERY - INSTALLATION).

(24) Connect negative battery cable.
(25) Refill cooling system (Refer to 7 - COOLING/

ENGINE - STANDARD PROCEDURE).

CAMSHAFT OIL SEAL

REMOVAL

(1) Disconnect and isolate negative battery cable.
(2) Remove front timing belt cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).

(3) Remove

timing

belt

and

tensioner/bracket

assembly (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT AND SPROCKETS - REMOVAL).

CAUTION: Do Not Rotate the camshaft or crank-
shaft when timing belt is removed damage to the
engine may occur.

(4) Hold camshaft sprocket with Special Tools

C-4687 and modified C-4687-1 as shown in (Fig. 32),
while removing attaching bolt.

(5) Remove sprocket from camshaft.

(6) Remove rear timing belt cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).

(7) Remove camshaft seal by carefully using a suit-

able pry tool. Be careful not to nick or damage the
camshaft seal surface or cylinder head seal retaining
bore.

CAUTION: Do not nick shaft seal surface or seal
bore.

(8) Shaft seal lip surface must be free of varnish,

dirt or nicks. Polish with 400 grit paper, if necessary.

Fig. 32 Modification to Special Tool

1 - GRIND LOCATION
2 - 12.7 MM (1/2 IN.)
3 - 50.8 MM (2 IN.)

9 - 36

ENGINE 2.0L SOHC

PL/SRT-4

CAMSHAFT (Continued)

INSTALLATION

(1) Install camshaft seal flush with cylinder head

using Special Tool MD998306 (Fig. 33).

(2) Install rear timing belt cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).

(3) Install the camshaft sprocket on the camshaft.

(4) Install camshaft sprocket retaining bolt. Hold

camshaft sprocket with Special Tools C-4687 and
modified C-4687-1 (Fig. 32) and tighten bolt to 115
N·m (85 ft. lbs.).

(5) Install

timing

belt

and

tensioner/bracket

assembly (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT AND SPROCKETS - INSTALLA-
TION).

(6) Install front timing belt cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).

(7) Connect negative battery cable.

SPARK PLUG TUBE

REMOVAL

(1) Remove the cylinder head cover. (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - REMOVAL)

(2) Using locking pliers, remove the tube from the

cylinder head (Fig. 34). Discard old tube.

INSTALLATION

(1) Clean area around spark plug with Mopar

parts cleaner or equivalent.

(2) Apply Mopar

t Stud and Bearing Mount or

equivalent to a new tube approximately 1 mm (0.039
in.) from the end in a 3 mm (0.118 in.) wide area.

(3) 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.

(4) Install the cylinder head cover. (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - INSTALLATION)

SPARK PLUG TUBE - SEAL

DESCRIPTION

The spark plug tube seals are located in the cylin-

der head cover (Fig. 35). 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 the cylinder head cover. (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - REMOVAL)

(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.

NOTE: Position seal with the concave side facing
the installation tool (Fig. 36).

Fig. 33 Camshaft Oil Seal - Installation

1 - SPECIAL TOOL MD 998306

Fig. 34 Spark Plug Tube - Removal

1 - LOCKING PLIERS
2 - SPARK PLUG TUBE

PL/SRT-4

ENGINE 2.0L SOHC

9 - 37

CAMSHAFT OIL SEAL (Continued)

Content .. 233 234 235 236 ..