Operation: Removal & Installation Dodge Neon II

REMOVAL

1. Raise vehicle.
2. Position oil collecting container under pressure switch location.
3. Disconnect oil pressure switch electrical connector and remove switch. (Scheme 155)

Scheme 155

INSTALLATION

1. Install oil pressure switch and connect electrical connector. (Scheme 155)
2. Lower vehicle.
3. Start engine and allow to run a minimum of 2 minutes.
4. Shut engine off and check engine oil level. Adjust level as necessary.

Scheme 156

Scheme 157

1. Disconnect negative cable from battery.
2. Remove front timing belt cover (Refer to «TIMING BELT COVER(S)»(ref-177391-S15538948382005052700000) ).
3. Remove timing belt. (Refer to «TIMING BELT AND SPROCKETS»(ref-177391-S13434889052005052700000) ).
4. Remove timing belt tensioner assembly. (Refer to «TIMING BELT TENSIONER ASSEMBLY»(ref-177391-S00137886752005052700000) ).
5. Remove the camshaft sprocket and the rear timing belt cover. (Refer to «TIMING BELT COVER(S)»(ref-177391-S15538948382005052700000) ).
6. Remove the oil pan. (Refer to «OIL PAN»(ref-177391-S36411593832005052700000) ).
7. Remove crankshaft sprocket using Special Tool 6793 and insert C-4685-C2. (Scheme 156)
8. Remove the oil pick-up tube.
9. Remove fasteners securing oil pump to engine block. Remove oil pump and front crankshaft seal. (Scheme 157)

Scheme 158

Scheme 159

1. To remove the relief valve, proceed as follows
2. Remove the threaded plug and gasket from the oil pump. (Scheme 158) CAUTION: Oil pump pressure relief valve must be installed as shown in or serious damage may occur. (Scheme 158)
3. Remove spring and relief valve. (Scheme 158)
4. Remove oil pump cover screws, and lift off cover.
5. Remove pump rotors.
6. Wash all parts in a suitable solvent and inspect carefully for damage or wear. (Scheme 159)

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

1. Clean all parts thoroughly. Mating surface of the oil pump should be smooth. Replace pump cover if scratched or grooved.
2. Lay a straightedge across the pump cover surface. (Scheme 160) If a 0.076 mm (0.003 in.) feeler gauge can be inserted between cover and straight edge, cover should be replaced.
3. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 7.64 mm (0.301 in.) or less, or if the diameter is 79.95 mm (3.148 in.) or less, replace outer rotor. (Scheme 161)
4. If inner rotor measures 7.64 mm (0.301 in) or less replace inner rotor. (Scheme 162)
5. Slide outer rotor into pump housing, press to one side with fingers and measure clearance between rotor and housing. (Scheme 163) If measurement is 0.39 mm (0.015 in.) or more, replace housing only if outer rotor is in specification.
6. Install inner rotor into pump housing. If clearance between inner and outer rotors is 0.203 mm (0.008 in.) or more, replace both rotors. (Scheme 164)
7. Place a straightedge across the face of the pump housing, between bolt holes. If a feeler gauge of 0.102 mm (0.004 inch) or more can be inserted between rotors and the straightedge, replace pump assembly. (Scheme 165) ONLY if rotors are in specs.
8. Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400-grit wet or dry sandpaper.
9. The relief valve spring has a free length of approximately 60.7 mm (2.39 in.) it should test between 18 and 19 pounds when compressed to 40.5 mm (1.60 in.). Replace spring that fails to meet specifications.
10. If oil pressure is low and pump is within specifications, inspect for worn engine bearings, damaged or missing oil pick-up tube O-ring, clogged oil pick-up tube screen, clogged oil filter and stuck open pressure relief valve or other reasons for oil pressure loss.

1. Position O-ring in the groove on adapter.
2. Align roll pin into engine block and tighten assembly to 80 N.m (60 ft. lbs.). see scheme 169
3. Install oil filter.