Neon, 2000-2005

Engine

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    After all components are installed on the engine, a DRB® scan tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

  2.  
  3. Properly recover the air conditioning system refrigerant.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Battery and battery tray
     
    Air intake duct from the intake manifold
     
    Throttle cables
     
    Electrical connectors
     
    Air cleaner assembly
     
    Upper radiator hose
     
    Fan module assembly
     
    Lower radiator hose
     
    Cooler lines if equipped with an automatic transaxle
     
    Clutch cable or hydraulic line as necessary, if equipped with a manual transaxle
     
    Shift linkage from the transaxle
     
    Transaxle electrical connections
     
    Engine wiring harness
     
    Powertrain Control Module (PCM)
     
    Positive cable from the Power Distribution Center (PDC)
     
    Ground wires
     
    Heater hoses
     
    Brake booster vacuum hose
     
    Coolant recovery hose
     
    Accessory drive belts
     
    Power steering pump and reservoir, move them aside
     
    Air conditioning compressor, if equipped
     

  12.  
  13. Raise the vehicle.

    Front wheels
     
    Right inner splash shield
     
    Halfshafts
     
    Power steering cooler, if equipped, and position it aside
     
    Downstream Oxygen (O 2 S) sensor connector
     
    Exhaust pipe from the manifold
     
    Exhaust system isolators and move exhaust rearward
     
    Lower engine torque strut
     
    Alternator, lower bracket and upper mounting bolt
     
    Structural collar
     
    Flywheel or flexplate, as applicable
     
    Bolt securing the power steering line to the engine block and reposition line.
     

  14.  
  15. Lower the vehicle.
  16.  
  17. Raise the vehicle enough to allow an Engine Dolly Tool 6135 and Cradle Tool 6710 to be placed under the engine.
  18.  
  19. 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 transaxle.
  20.  
  21. Install safety straps around the engine to the cradle; tighten the straps and lock them into position.
  22.  
  23. Raise the vehicle enough to see if the straps are tight enough to hold the cradle assembly to the engine.
  24.  
  25. Lower the vehicle so the weight of the engine and transaxle ONLY is on the cradle.
  26.  
  27. Remove the upper engine torque strut.
  28.  
  29. Remove the right and left engine/transaxle mount through-bolts.
  30.  
  31. Raise the vehicle slowly, until it is about 6 inch (15cm) above normal engine mount locations.
  32.  
  33. Remove the alternator.
  34.  
  35. Lower bracket and upper mounting bolt.
  36.  
  37. Continue raising the vehicle until the engine/transaxle assembly clears the compartment.
    NOTE
    If may be necessary to move the engine/transaxle assembly with the cradle to clear the body flanges.



    Click image to see an enlarged view

    Fig. Exploded view of the torque struts and bracket-2.0L engine

    Exploded view of the torque struts and bracket-2.0L engine

    Click image to see an enlarged view

    Fig. Exploded view of the left mount bracket-2.0L engine

    Exploded view of the left mount bracket-2.0L engine

    Click image to see an enlarged view

    Fig. Exploded view of the left mount-Automatic transaxle-2.0L engine

    Exploded view of the left mount-Automatic transaxle-2.0L engine

    Click image to see an enlarged view

    Fig. Exploded view of the left mount-Manual transaxle 2.0L engine

    Exploded view of the left mount-Manual transaxle 2.0L engine

    Click image to see an enlarged view

    Fig. Exploded view of the right mount-2.0L engine

    Exploded view of the right mount-2.0L engine

    Click image to see an enlarged view

    Fig. Exploded view of the right mount bracket-2.0L engine

    Exploded view of the right mount bracket-2.0L engine

    Click image to see an enlarged view

    Fig. Exploded view of the structural collar-2.0L engine

    Exploded view of the structural collar-2.0L engine

    Click image to see an enlarged view

    Fig. View of the engine cradle and dolly-2.0L engine

    View of the engine cradle and dolly-2.0L engine
  38.  

To install:

  1. Install or connect the following:

    Engine/transmission assembly to the vehicle and torque the engine mount bolts to 87 ft. lbs. (118 Nm)
     
    Upper engine torque strut and remove the engine safety straps
     

  2.  
  3. Slowly raise the vehicle enough to remove the engine dolly and cradle.

    Alternator, lower bracket and upper mounting bolt
     
    Halfshafts
     
    Flywheel or flexplate
     
    Bolt securing the power steering line to the engine block
     
    Power steering cooler screws, if equipped
     
    Dust shield
     
    Lateral bending brace
     

  4.  
  5. Install the structural collar and torque the bolts, in 3 steps, using the following procedure:
    1. Step 1: Collar-to-oil pan bolts to 30 inch lbs. (3 Nm).
    2.  
    3. Step 2: Collar-to-transaxle bolts to 80 ft. lbs. (108 Nm).
    4.  
    5. Step 3: Collar-to-oil pan bolts to 40 ft. lbs. (54 Nm).
    6.  

  6.  
  7. Install or connect the following:
    NOTE
    If equipped with a hydraulic clutch, it will not be necessary to bleed the system. The quick-connect fittings used on this system close immediately after disconnection and don-t allow any fluid to leak out.



    Lower engine torque strut and torque the through-bolts to 87 ft. lbs. (118 Nm)
     
    Exhaust system isolators
     
    Exhaust pipe to the manifold. Tighten the exhaust fasteners to 21 ft. lbs. (28 Nm)
     
    Downstream O 2 S sensor connector
     
    A/C compressor, if equipped
     
    Drive belts
     
    Right inner splash shield
     
    Front wheels, then lower vehicle
     
    Power steering pump and reservoir
     



    Clutch cable/hydraulic line if equipped with a manual transaxle
     
    Automatic transaxle cooler lines, if equipped
     
    Shift linkage to the transaxle
     
    Transaxle electrical connectors
     
    Fuel lines
     
    Heater hoses
     
    Ground wires
     
    PCM
     
    Engine wire harness
     
    Lower radiator hose
     
    Fan module assembly
     
    Upper radiator hose
     
    Air cleaner assembly
     
    Electrical connectors
     
    Throttle cables
     
    Air intake duct to the intake manifold
     
    Battery and battery tray
     

  8.  
  9. Fill the engine with clean oil.
  10.  
  11. Fill the cooling system.
  12.  
  13. After all components are installed, perform the camshaft and crankshaft timing relearn procedure as follows:
    1. Connect a DRB® scan tool to the DLC (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.  

  14.  
  15. If equipped with air conditioning, recharge the system.
  16.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    After all components are installed on the engine, a DRB® scan tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

  2.  
  3. Properly recover the air conditioning system refrigerant.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Matchmark the drive plate-to-clutch module bolts before removing them.



    Air cleaner housing
     
    Battery cables, battery and battery tray
     
    Throttle and speed control cables from the throttle body
     
    Engine wiring harness from the Powertrain Control Module (PCM)
     
    Positive cable from the Power Distribution Center (PDC) and ground wire from vehicle body
     
    Bolts attaching PDC and set aside
     
    Wiring connectors at lower battery tray support
     
    Ground wire from the vehicle body-to-engine at the right side strut tower
     
    Brake booster vacuum hose from intake manifold
     
    Proportional purge hose from the throttle body
     
    Coolant reserve/recovery hose from coolant outlet connector
     
    Heater hoses
     
    Upper and lower radiator hoses
     
    Upper A/C line from A/C condenser
     
    A/C lines at junction near upper torque strut
     
    Clutch hydraulic line, using Special Tool 6638A
     
    Transmission shift linkage
     
    Transmission electrical connectors
     
    Power steering hoses from radiator
     
    Radiator fan electrical connector and cooling module assembly
     
    Front wheels
     
    Right inner splash shield
     
    Halfshafts
     
    Accessory drive belts
     
    Alternator and support brackets
     
    Charge air cooler hoses
     
    Downstream Oxygen Sensor (O 2 S) connector
     
    Exhaust system from manifold
     
    Both power steering hoses from steering gear
     
    Upper and lower heat shields, elbow support bracket, turbocharger support bracket, and elbow
     
    Structural collar
     



    Drive plate to clutch module bolts
     
    Lower engine torque strut

    Click image to see an enlarged view

    Fig. Exploded view of the torque struts-2.4L engine

    Exploded view of the torque struts-2.4L engine
     
    A/C compressor
     
    Fluid lines from power steering pump and the pump
     

  12.  
  13. Raise vehicle enough to allow engine dolly, cradle, and posts, (Special Tools 6135, 6710, and 6848) to be installed under vehicle.
  14.  
  15. Loosen the engine support posts to allow movement for positioning onto engine locating holes and flange on the engine bedplate. Lower the vehicle and position the cradle until the engine is resting on the support posts. Tighten the mounts to cradle frame. This will keep support posts from moving when removing or installing the engine and transmission assembly.
    CAUTION
    You MUST use safety straps.

  16.  
  17. Install safety straps around the engine to cradle. Tighten straps and lock them into position.
  18.  
  19. Raise vehicle enough to determine if the straps are secure enough to hold the cradle assembly to the engine.
  20.  
  21. Lower the vehicle so weight of the engine and transmission ONLY is on the cradle assembly.
  22.  
  23. Remove or disconnect the following:

    Upper engine torque strut
     
    Right mount through bolt and left mount attaching bolts
     

  24.  
  25. Raise the vehicle slowly until the engine/transaxle assembly clears the engine compartment. You may need to move the assembly with the cradle to allow for removal around body flanges.

    Click image to see an enlarged view

    Fig. View of the right mount-2.4L engine

    View of the right mount-2.4L engine

    Click image to see an enlarged view

    Fig. View of the left mount-2.4L engine

    View of the left mount-2.4L engine

    Click image to see an enlarged view

    Fig. Proper positioning of the engine cradle-2.4L engine

    Proper positioning of the engine cradle-2.4L engine
  26.  

To install:

  1. Install or connect the following:
    WARNING
    To prevent damaging the lower shield, you must install the upper shield first.


    NOTE
    You do not have to bleed the clutch. The quick-connect fittings seal closed immediately after disconnection and no air can get in the system



    Position the engine and transmission assembly under the vehicle and slowly lower the vehicle over the engine/transaxle assembly. Continue lowering vehicle until the engine/transaxle aligns to mounting locations.
     
    Mounting bolts at the right and left engine/transaxle mounts. Torque the bolts to 87 ft. lbs. (118 Nm)
     
    Upper engine torque strut. Remove the safety straps from engine/transaxle assembly. Slowly raise the vehicle enough to remove the engine dolly and cradle.
     
    Power steering pump
     
    Fluid lines to power steering pump
     
    A/C compressor
     
    Lower engine torque strut
     
    Drive plate to clutch module bolts
     
    Structural collar
     



    Elbow, turbocharger support bracket, elbow support bracket, and upper and lower heat shields
     
    Power steering hoses to the steering gear
     
    Exhaust system to the manifold
     
    Downstream O 2 S
     
    Charge air cooler hoses
     
    Alternator and mounting brackets
     
    Accessory drive belts
     
    Halfshafts
     
    Right inner splash shield
     
    Wheels
     
    Cooling module assembly, and connect the radiator fan electrical connector
     
    Power steering hoses to the radiator
     
    Clutch hydraulic line
     
    Transmission shift linkage and electrical connectors
     



    A/C lines at junction near the upper torque strut
     
    Upper A/C line to the A/C condenser
     
    Upper and lower radiator hoses
     
    Fuel line and heater hoses
     
    Coolant reserve/recovery hose to the coolant outlet connector
     
    Brake booster vacuum hose to the intake manifold
     
    Proportional purge hose to the throttle body
     
    Ground straps, and connect all engine wiring
     
    PDC and retaining bolts
     
    Positive battery cable to the PDC and ground wire to the vehicle body
     
    Engine wiring harness to the PCM
     
    Throttle and speed control cables
     
    Battery tray, battery and cables
     
    Air cleaner housing assembly and clean air hose
     
    Oil filter. Fill engine with proper type and amount of oil
     

  2.  
  3. Fill power steering and engine cooling systems.
  4.  
  5. Evacuate and recharge A/C system.
  6.  
  7. Start the engine and run until operating temperature is reached. Check for leaks.
  8.  
  9. Perform torque strut adjustment procedure, as follows:
    1. Remove the accessory drive belt splash shield.
    2.  
    3. Remove the pencil strut.
    4.  
    5. Loosen the upper and lower torque strut attaching bolt at the suspension crossmember and shock tower bracket.
    6.  
    7. Adjust the engine position by placing a floor jack on the forward edge of the transmission bell housing

      Click image to see an enlarged view

      Fig. Position the floor jack properly to prevent upward lifting of the engine-2.4L engine

      Position the floor jack properly to prevent upward lifting of the engine-2.4L engine
    8.  
    9. With the engine supported, remove the upper and lower torque strut attachment bolt(s) at shock tower bracket and suspension crossmember. Make sure the torque struts are free to move within the shock tower bracket and crossmember. Reinstall the torque strut bolt(s), but do not tighten yet.
    10.  
    11. Apply upward force, allowing the upper engine to rotate rearward until the distance between the center of the rearmost attaching bolt on the engine mount bracket (point A) and the center of the hole on the shock tower bracket (point B) is 4.70 inch (119mm)
      WARNING
      Hold the engine in position with the jack until the upper and lower torque strut bolts are tightened.



      Click image to see an enlarged view

      Fig. Measure the distance between the center of the rearmost attaching bolt on the engine mount bracket (point A) and the center of the hole on the shock tower bracket (point B)-2.4L engine

      Measure the distance between the center of the rearmost attaching bolt on the engine mount bracket (point A) and the center of the hole on the shock tower bracket (point B)-2.4L engine
    12.  
    13. With the engine held at the proper position, tighten both the upper and lower torque strut bolts to 85 ft. lbs. (115 Nm)
    14.  
    15. Remove the floor jack.
    16.  
    17. Install the pencil strut and tighten nuts to 43 ft. lbs. (58 Nm).
    18.  

  10.  
  11. Install the accessory drive belt splash shield.
  12.  
  13. Adjust transmission linkage, if necessary.
  14.  

 
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