Operation: Other Dodge Neon II

CLEANING

Clean camshaft with a suitable solvent.

Scheme 60

1. Inspect camshaft bearing journals for damage and binding. (Scheme 60) 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) and replace camshaft if out of limit. (Scheme 60) Standard value is 0.0254 mm (0.001 in.), wear limit is 0.254 mm (0.010 in.).

Scheme 61

1. Lubricate the camshaft journals with oil.
2. Carefully install the camshaft into the cylinder head. Reposition the PDC and heater tubes for clearance. see scheme 58
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.
5. Measure camshaft end-play. (Refer to «STANDARD PROCEDURE - CAMSHAFT END-PLAY»(ref-177391-S06582003472005060100000) ). NOTE: Camshaft must be installed before installation of the camshaft seal.
6. Install camshaft seal. (Refer to «CAMSHAFT OIL SEAL»(ref-177391-S36772559682005060100000) ).
7. Install rear timing belt cover. (Refer to «TIMING BELT COVER(S)»(ref-177391-S15538948382005052700000) ).
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 modified Adaptor C-4687-1, tighten attaching bolt to 115 N.m (85 ft. lbs.).
10. Install timing belt and tensioner. (Refer to «TIMING BELT AND SPROCKETS»(ref-177391-S13434889052005052700000) ).
11. Install front timing belt cover. (Refer to «TIMING BELT COVER(S)»(ref-177391-S15538948382005052700000) ).
12. Install rocker arm assemblies in correct order as removed. Tighten the rocker arm assemblies in sequence shown in (Scheme 61) to 28 N.m (250 in. lbs.).
13. Install the cylinder head cover. (Refer to «CYLINDER HEAD COVER»(ref-177391-S15136192452005060100000) ).
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 «BATTERY & CHARGING SYSTEMS»(ref-177669) ).
20. Install the air cleaner housing assembly. (Refer to «AIR CLEANER HOUSING»(ref-177391-S10665184012005060100000) ).
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 «BATTERY & CHARGING SYSTEMS»(ref-177669) ).
24. Connect negative battery cable.
25. Refill cooling system. (Refer to «COOLING SYSTEMS»(ref-177701) ).
26. Perform camshaft and crankshaft timing relearn procedure as follows: Connect the DRB III® 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. Turn the ignition switch on. Access "Engine" diagnostics. Select "Miscellaneous" option. Select "Re-Learn Cam Crank" option and follow directions on DRBIII® screen.

Scheme 62

Scheme 63

Scheme 64

1. Disconnect make-up air and PCV hoses from cylinder head cover. ( (Scheme 62) and (Scheme 63) ).
2. Remove ignition coil and spark plug cables. (Scheme 64)
3. Remove cylinder head cover bolts.
4. Remove cylinder head cover.

Clean cylinder head and cover mating surfaces using a suitable solvent.