Chrysler Neon 1995-1999 Repair Guide

Engine

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4 and 5

In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as disconnect the exhaust system'' or remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this guide.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
 
After unbolting the transmission or transaxle, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
 
After the engine is clear of the compartment, place it on an engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this guide.
 

  1. If equipped with A/C, take the vehicle to a reputable repair shop to the have the system discharged and evacuated.
  2.  

If your vehicle is equipped with air conditioning, refer to General Information & Maintenance for information regarding the implications of servicing your A/C system yourself. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Properly relieve the fuel system pressure, as outlined in Fuel System of this guide.
  2.  
  3. Disconnect the negative, then the positive battery cables. Remove the battery and the battery tray. Set the PCM aside.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Remove the upper radiator hose, radiator and fan module assembly. Remove the lower radiator hose.
  8.  
  9. If equipped with an automatic transaxle, disconnect and plug the transaxle cooler lines.
  10.  
  11. Disconnect the clutch cable (manual transaxles) and transmission shift linkage.
  12.  
  13. Disconnect the throttle body linkage.
  14.  
  15. Detach the engine wiring harness.
  16.  
  17. Disconnect the heater hoses.
  18.  
  19. Raise and safely support the vehicle, then remove the right inner splash shield.
  20.  
  21. Remove the accessory drive belts.
  22.  
  23. Remove the halfshafts, as outlined in Drive Train of this guide.
  24.  
  25. Disconnect the exhaust pipe from the manifold.
  26.  
  27. Support the engine and transaxle assembly with a suitable jack, then remove the front engine mount.
  28.  



Click image to see an enlarged view

Fig. Fig. 1: Front engine mount location and bolt identification

  1. On 1996-99 vehicles equipped with manual transaxle, remove the power hop damper.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: On vehicles with manual transaxles, you must remove the power hop damper

  1. Carefully lower the vehicle.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Unbolt the power steering pump and reservoir and position them aside.
  6.  
  7. If equipped, remove the A/C compressor.
  8.  
  9. Remove the ground straps to body.
  10.  
  11. Raise the vehicle enough to allow a suitable engine dolly and cradle to be placed under the engine.
  12.  
  13. Loosen the engine support posts in order to allow movement for positioning onto the engine locating holes and flange on the engine bedplate. Carefully lower the vehicle and position the cradle until the engine is resting on the support posts. Tighten the mounts to the cradle frame. This will keep the support posts from moving when removing or installing the engine and transmission.
  14.  



Click image to see an enlarged view

Fig. Fig. 3: You must use a suitable engine dolly and cradle in order to remove the engine

  1. Install safety straps around the engine to the cradle; tighten straps and lock them into position.
  2.  
  3. Raise the vehicle enough to see if the straps are tight enough to hold the cradle assembly to the engine.
  4.  
  5. Lower the vehicle so the weight of the engine and transaxle ONLY is on the cradle.
  6.  
  7. Remove the engine and transaxle mount through-bolts.
  8.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the left engine mount



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Fig. Fig. 5: Location of the right engine mount

  1. Raise the vehicle slowly, it might be necessary to move the engine/transaxle assembly with the cradle to allow to remove around the body flanges.
  2.  

To install:
  1. Installation is the reverse of the removal procedure. Please note the following important steps.
  2.  
  3. Tighten the front engine mount retainers as follows (bolt specifications are on accompanying figure:
    1. If the engine mount bracket was removed, tighten bolt 1 to 20 inch lbs. (3 Nm) and bolts 2, 3 and 4 to 80 ft. lbs. (108 Nm).
    2.  
    3. If the engine mount bracket was removed, tighten bolts 5 and 1 to 40 ft. lbs. (54 Nm).
    4.  
    5. Tighten the engine mount bracket-to-insulator assembly through-bolt to 40 ft. lbs. (54 Nm).
    6.  
    7. Tighten the insulator assembly nuts to the lower radiator crossmember torque to 40 ft. lbs. (54 Nm).
    8.  
    9. Tighten the mass damper bolt to 40 ft. lbs. (54 Nm).
    10.  

  4.  
  5. Tighten the left engine mount as follows:
    1. To 40 ft. lbs. (54 Nm) for (A) fasteners
    2.  
    3. To 80 ft. lbs. (108 Nm) for (B) fasteners.
    4.  

  6.  
  7. Tighten the right engine mount as follows:
    1. Engine mount-to-rail fasteners to 40 ft. lbs. (54 Nm).
    2.  
    3. Engine mount-to-engine bracket to 80 ft. lbs. (108 Nm).
    4.  

  8.  
  9. Tighten the power hop damper retainers to 40 ft. lbs. (54 Nm).
  10.  

  1. After all components are installed, perform the camshaft and crankshaft timing relearn procedure as follows:
    1. Connect a DRB or equivalent scan tool to the Data Link Connector (located under the instrument panel, near the steering column).
    2.  
    3. Turn the ignition switch ON , and access the miscellaneous screen.
    4.  
    5. Select re-learn cam/crank option and follow the directions on the scan tool screen.
    6.  

  2.  
  3. If equipped with A/C, take your vehicle to a reputable repair shop to have the A/C system recharged.
  4.  

 
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