Repair Procedure

1. Remove the accessory drive belts using the procedure in the 2000 Neon Service Manual (publication No. 81-270-0025) 7-24.

2. Raise the vehicle on a suitable hoist.

3. Remove the right side splash shield.

4. Remove the crankshaft damper.





5. Remove the bolts attaching the lower strut to crossmember and strut bracket (Figure 1).

6. Remove the lower torque strut.

7. Lower the vehicle.

8. Remove the bolts attaching the upper torque strut to the shock tower bracket and engine mount bracket (Figure 1).

9. Remove the upper torque strut.

10. Remove the ground strap and power steering hose support clip from the engine mount bracket.

11. Remove the power steering pump and set aside.

12. Support engine with a suitable jack.





13. Remove the bolt access cover and bolt attaching the right engine mount to mount bracket (Figure 2).

14. To remove the engine mount bracket, remove the three bolts attaching the bracket to the front of the engine block.

NOTE:
THE ENGINE MOUNT BRACKET REMOVAL REQUIRES RAISING THE ENGINE TO PROVIDE CLEARANCE BETWEEN THE FRAME RAIL AND ENGINE.

NOTE:
THE RIGHT ENGINE MOUNT ATTACHING HOLES ARE SLIGHTLY OVERSIZE TO COMPENSATE FOR MANUFACTURING TOLERANCES. THE MOUNT HAS BEEN SET AT THE MANUFACTURING PLANT FOR PROPER POWERTRAIN ALIGNMENT. THEREFORE, IT IS NECESSARY TO MARK THE POSITION OF THE MOUNT BEFORE THE ATTACHING BOLTS ARE LOOSENED.

15. Using a permanent ink marker or equivalent, mark the position of engine mount to the body frame rail.





16. Remove the bolts attaching mount to the body (Figure 3).

17. Remove mount between engine and body frame rail. Mount removal may require engine position to be raised or lowered to allow mount removal clearance.

18. Position new mount (P/N 04668192AC) into the original position of discarded mount on body frame rail.

CAUTION:
THE ENGINE MOUNT MUST BE INSTALLED IN THE ORIGINAL POSITION ON THE BODY FRAME RAIL.

19. Ensure the new mount maintains the originally marked position and install mount bolts. Torque the bolts to 28 Nm (250 in.lbs.) (Figure 3).

20. Install the engine mount bracket and torque bolts to 61 Nm (45 ft.lbs).

21. Install bolt attaching the right engine mount to bracket and torque to 118 Nm (87 ft.lbs) (Figure 2).

22. Remove the support from under the engine.

23. Install the power steering pump.

24. Install the power steering hose support clip and ground strap.

25. Raise the vehicle on a suitable hoist.

26. Position the lower torque strut into mounting location.

27. Install the mounting bolts.

28. Install the crankshaft damper.

29. Install the generator belt.

30. Install the right side splash shield.

31. Lower the vehicle.

32. Position the upper torque strut into mounting locations.

33. Install the mounting bolts.

NOTE:
THE UPPER AND LOWER TORQUE STRUTS NEED TO BE ADJUSTED TOGETHER TO ASSURE PROPER ENGINE POSITIONING AND ENGINE MOUNT LOADING. WHENEVER A TORQUE STRUT BOLT(S) IS LOOSENED THE TORQUE STRUT ADJUSTMENT MUST BE PERFORMED.

34. Loosen the upper and lower torque strut attaching bolt at the suspension crossmember and shock tower bracket.





35. The engine position may now be adjusted by positioning a suitable floor jack on the forward edge of the transmission bell housing (Figure 4).

NOTE:
THE FLOOR JACK MUST BE POSITIONED AS SHOWN IN FIGURE 4 TO PREVENT MINIMAL UPWARD LIFTING OF THE ENGINE.





36. **Carefully apply upward force, allowing the upper engine to rotate rearward until the distance between the center of the rearmost attaching stud on the engine mount bracket (point "A") and the center of the hole for the washer hose clip on the shock tower bracket (point "B") is 119 mm (4.70 in.) (Figure 5). Torque the upper strut bolts to 118 Nm (87 ft. lbs.).**





37. **Adjust the lower torque strut to allow a distance of 262 mm (10.30 in.) from the center point of the bolt in the torque strut bracket (point "A") and the center of the bolt in the crossmember (point "B") (Figure 6). Torque the bolts to 118 Nm (87 ft. lbs.).**

38. Remove the floor jack.

39. Install the accessory drive belts.

40. Attempt to move the radiator in the upper radiator mounting brackets. If the radiator moves freely in both brackets, no further action is required. If the radiator does not move freely or appears to be bound, proceed to step 41.





41. Remove the right and left upper radiator mounting bracket bolts (Figure 7).

42. Reposition the right and left upper radiator mounting brackets so they are perpendicular to the upper radiator crossmember (Figure 7).

43. Install the right and left mounting bolts and torque to 12.4 Nm (110 in. lbs.).

44. Check radiator to insure free movement in both the left and right upper radiator mounting brackets.