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Dodge, Plymouth Neon Repair Manual 2000-2005

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This Chilton repair and service manual covers 2000-2005 Dodge Neon and 2000-2005 Plymouth Neon automobiles, U.S. and Canadian edition.

Easy-to-understand how-to instructions with hundreds of clear, close-up photos of each task while it's being performed. Perfect for the DIY mechanic wanting to maintain, service or repair one of these cars.

Note: This manual DOES NOT include information specific to SRT-4 models.


Book Excerpt: 2000-2005 Dodge Neon, Plymouth Neon Repair Manual

ENGINE | VALVE LASH ADJUSTERS

REMOVAL, INSPECTION AND INSTALLATION

Note: the valve lash adjuster is an integral part of each rocker arm and cannot be replaced separately.

  1. Remove the rocker arm shafts (see Section 10). Don?t remove the rocker arms from the shafts.
  2. Turn the rocker arm assembly upside down on the workbench. Inspect each lash adjuster carefully for signs of wear and damage, particularly on the surface that contacts the valve tip. Since the lash adjusters frequently become clogged, we recommend replacing the rocker arm/lash adjuster assembly if you?re concerned about their condition or if the engine is exhibiting valve ?tapping? noises.
  3. If any are removed, assemble the rocker arms onto their shaft(s) (see Section 10).
  4. The lash adjusters must be partially full of engine oil ? indicated by little or no plunger action when the adjuster is depressed. If there?s excessive plunger travel, place the rocker arm assembly into clean engine oil and pump the plunger until the plunger travel is eliminated. Note: If the plunger still travels within the rocker arm when full of oil it?s defective and the rocker arm assembly must be replaced.
  5. When re-starting the engine after replacing the rocker arm/lash adjusters, the adjusters will normally make ?tapping? noises.

    After warm-up. raise the speed of the engine from idle to 3,000 rpm for one minute. If the adjuster(s) do not become silent, replace the defective rocker arm/lash adjuster assembly(ies).

WARNING! Allow the engine to cool completely before beginning the next procedure.

REMOVAL
(Refer to illustrations 13.4, 13.10a and 13.10b)

  1. Position the number one piston at Top Dead Center (see Section 3).
  2. Disconnect the cable from the negative battery terminal (see Chapter 5).
  3. Drain the cooling system and remove the spark plugs (see Chapter 1).
  4. Remove the intake manifold (see Section 5). Cover the intake ports with duct tape to keep out debris (see illustration).
  5. If necessary, remove the exhaust manifold (see Section 6).
  6. NOTE: On some models, the exhaust manifold is easier to remove after the cylinder head is removed.

  7. Remove the ignition system components (see Chapter 5).
  8. Remove the valve cover (see Section 4).
  9. Remove the timing belt (see Section 7).
  10. Loosen the cylinder head bolts, turn at a time, in the reverse of the tightening sequence (see illustration 13.14) until they can be removed by hand.
  11. NOTE: Write down the location of the different length bolts so they will be reinstalled in the correct location.

  12. Carefully lift the cylinder head (see illustration) straight up and place the head on wood blocks to prevent damage to the sealing surfaces.

    If the head sticks to the engine block, dislodge it by placing a wood block against the head casting and tapping the wood with a hammer or by prying the head with a prybar placed carefully on a casting protrusion (see illustration).


AUTOMATIC TRANSAXLE
REMOVAL
(Refer to illustrations 4.5, 4.7, 4.9, 4.10 and 4.11)
  1. In the event of hard shifting, disconnect the cable at the transaxle and operate the shifter from the driver?s seat. If the shift lever moves smoothly through all positions with the cable disconnected, then the cable should be adjusted as described at the end of this Section. To remove and install the shift cable, perform the following:
  2. Raise the hood and place a blanket over the left (driver?s) fender to protect it.
  3. Remove the air filter housing (see Chapter 4).
  4. Remove the battery and battery tray (see Chapter 5).
  5. Working in the engine compartment, disconnect the shift cable from the shift lever (see illustration).
  6. Working in the engine compartment, disconnect the shift cable from the bracket.
  7. Working inside the vehicle remove the shift knob set screw and remove the knob from the shifter (see illustration).
  8. Remove the center console (see Chapter 11).
  9. Remove gearshift indicator lamp from the shift trim bezel (see illustration).
  10. Remove the shift trim bezel screws and the bezel (see illustration).
  11. Use a flat-blade screwdriver and carefully pry the shift cable from the shift lever mounting stud (see illustration).
  12. Carefully pull the cable conduit end out from the shift housing. Pull up and remove the cable.
  13. Remove the grommet plate-to-floor-pan fasteners.
  14. Raise the vehicle and support it securely on jackstands.
  15. Working under the vehicle, remove the catalytic converter heat shield and the intermediate pipe heat shield (see Chapter 6).
  16. Working in the passenger compartment, remove the last remaining grommet fastener and remove the cable from the vehicle.

Subject: 2000, 2001, 2002, 2003, 2004, 2005 Dodge, Plymouth Neon service, maintenance, repair info. ISBN-10: 1563926709 | ISBN-13: 9781563926709 | Chilton 20601

TABLE of CONTENTS:

Introduction: About this manual | Introduction | Vehicle identification numbers | Maintenance techniques, tools and working facilities | Buying parts | Jacking and towing | Booster battery (jump) starting | Conversion factors | Automotive chemicals and lubricants | Safety first! | Troubleshooting

  • Tune-up and routine maintenance
  • Engine and overhaul procedures
  • Cooling, heating and air-conditioning systems
  • Fuel and exhaust systems
  • Engine electrical systems
  • Emissions control systems
  • Manual and automatic transaxle
  • Clutch and driveaxles
  • Brakes
  • Suspension and steering systems
  • Body
  • Chassis electrical system
  • Wiring diagrams

  • Publisher: Chilton Manuals
  • Pages: 306 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.25 x 10.75 inches
  • ISBN: 978-1-56392-670-9
  • Years: 2000 - 2005