Dodge Neon / Neon SRT-4. Manual - part 252

(41) Loosen engine support posts to allow move-

ment for positioning onto engine locating holes and
flange on the engine bedplate. Lower vehicle and
position cradle until the engine is resting on support
posts (Fig. 13). Tighten mounts to cradle frame. This
will keep support posts from moving when removing
or installing engine and transmission.

(42) Install safety straps around the engine to cra-

dle (Fig. 13). Tighten straps and lock them into posi-
tion.

WARNING: Safety straps MUST be used.

(43) Raise vehicle enough to determine if straps

are secure enough to hold cradle assembly to engine.

(44) Lower vehicle so weight of the engine and

transmission ONLY is on the cradle assembly.

(45) Remove the upper engine torque strut.
(46)

Remove right mount through bolt (Fig. 11)

and left mount attaching bolts (Fig. 12).

(47) Raise vehicle slowly until engine/transaxle

assembly clears engine compartment. It may be nec-
essary to move the engine/transmission assembly
with the cradle to allow for removal around body
flanges.

INSTALLATION - ENGINE ASSEMBLY

(1) Position engine and transmission assembly

under vehicle and slowly lower the vehicle over the
engine/transaxle assembly.

(2) Continue lowering vehicle until engine/trans-

axle aligns to mounting locations. Install mounting
bolts at the right and left engine/transaxle mounts
(Fig. 11) and (Fig. 12). Tighten bolts to 118 N·m (87
ft. lbs.).

(3) Install upper engine torque strut.
(4) Remove safety straps from engine/transaxle

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

(5) Install power steering pump.

(6) Connect power steering lines to power steering

pump.

(7) Install A/C compressor.
(8) Install lower engine torque strut (Refer to 9 -

ENGINE/ENGINE MOUNTING/TORQUE STRUT -
INSTALLATION).

(9) Install drive plate to clutch module bolts.
(10) Install structural collar (Refer to 9 - ENGINE/

ENGINE

BLOCK/STRUCTURAL

COLLAR

INSTALLATION).

NOTE: The upper shield must be installed first to
prevent fatiguing the lower shield.

(11) Install elbow, turbocharger support bracket,

elbow support bracket, and upper and lower heat
shields (Fig. 10).

(12) Connect both power steering hoses to steering

gear (Fig. 9).

(13) Connect exhaust system to manifold (Fig. 8).
(14) Connect the downstream oxygen sensor.
(15) Install charge air cooler hoses (Refer to 11 -

EXHAUST

SYSTEM/TURBOCHARGER

SYSTEM/

CHARGE

AIR

COOLER

AND

PLUMBING

INSTALLATION).

(16) Install

generator

and

mounting

brackets

(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).

(17) Install accessory drive belts (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

INSTALLATION).

(18) Install axle shafts (Refer to 3 - DIFFEREN-

TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION).

(19) Install right inner splash shield.
(20) Install wheels and lower vehicle.

Fig. 11 Right Mount Through Bolt

1 - BOLT
2 - RIGHT ENGINE MOUNT
3 - ENGINE MOUNT BRACKET

Fig. 12 Left Mount Bolts

1 - BOLT
2 - TRANSAXLE
3 - LEFT MOUNT

9 - 102

ENGINE 2.4L DOHC TURBO

PL/SRT-4

ENGINE 2.4L DOHC TURBO (Continued)

(21) Install cooling module assembly, and connect

radiator fan electrical connector.

(22) Connect power steering hoses to radiator.
(23) Connect clutch hydraulic line (Fig. 5).
(24) Connect transmission shift linkage.
(25) Connect transmission electrical connectors.

NOTE: It is not necessary to bleed the clutch
hydraulic system. The quick-connect fittings close
immediately after disconnection; allowing no fluid
to escape.

(26) Connect A/C lines at junction near upper

torque strut.

(27) Connect upper A/C line to A/C condenser.
(28) Install upper and lower radiator hoses.
(29) Connect fuel line and heater hoses.
(30) Connect coolant reserve/recovery hose to cool-

ant outlet connector.

(31) Connect brake booster vacuum hose to intake

manifold.

(32) Connect the proportional purge hose to throt-

tle body.

(33) Install all ground straps and connect engine

wiring harness.

(34) Position PDC and install bolts.
(35) Connect positive battery cable to PDC and

ground wire to vehicle body.

(36) Connect engine wiring harness at Powertrain

Control Module (PCM).

(37) Connect throttle and speed control cables.
(38) Install battery tray and battery (Refer to 8 -

ELECTRICAL/BATTERY

SYSTEM/BATTERY

INSTALLATION).

(39) Connect cables to battery.
(40) Install air cleaner housing assembly and con-

nect clean air hose (Refer to 9 - ENGINE/AIR
INTAKE

SYSTEM/AIR

CLEANER

HOUSING

INSTALLATION).

(41) Install oil filter. Fill engine crankcase with

proper oil to correct level.

(42) Fill power steering system.
(43) Fill cooling system (Refer to 7 - COOLING/

ENGINE - STANDARD PROCEDURE).

(44) Evacuate and recharge A/C system (Refer to

24 - HEATING & AIR CONDITIONING - STAN-
DARD PROCEDURE).

(45) Start engine and run until operating temper-

ature is reached.

(46) Perform torque strut adjustment procedure

(Refer

ENGINE/ENGINE

MOUNTING/

TORQUE STRUT - ADJUSTMENTS).

(47) Adjust transmission linkage, if necessary.

Fig. 13 Positioning Engine Cradle Support Post

1 - POST LOCATING HOLES IN BLOCK
2 - POST POSITIONED UNDER BRACKET
3 - POST LOCATING HOLE IN STRUT
4 - SAFETY STRAPS

5 - FLOOR JACK
6 - SPECIAL TOOL 6848
7 - SPECIAL TOOL 6135
8 - SPECIAL TOOL 6710

PL/SRT-4

ENGINE 2.4L DOHC TURBO

9 - 103

ENGINE 2.4L DOHC TURBO (Continued)

SPECIFICATIONS

2.4L ENGINE

GENERAL SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Metric

Standard

Type

In-Line OHV, DOHC

Number of
Cylinders

Firing Order

1-3-4-2

Compression
Ratio

8.1:1

Max. Variation
Between
Cylinders

25%

Displacement

2.4 Liters

148 cu. in.

Bore

87.5 mm

3.445 in.

Stroke

101.0 mm

3.976 in.

Compression
Pressure

1172-1551 kPa

170-225 psi

CYLINDER BLOCK

DESCRIPTION

SPECIFICATION

Metric

Standard

Cylinder Bore
Diameter

87.4924-

87.5076 mm

3.4446-3.4452

in.

Out-of-Round
(Max.)

0.051 mm

0.002 in.

Taper (Max.)

0.051 mm

0.002 in.

PISTONS

DESCRIPTION

SPECIFICATION

Metric

Standard

Piston Diameter

87.436-87.454

3.4424-3.4431

in.

Clearance @ 22
mm (0.866 in.)
from bottom of
skirt

0.046-0.064

0.0018-0.0025

in.

Weight

345-355 grams

12.17-12.52 oz.

Land Clearance
(Diametrical)

0.556-0.674

0.021-0.027 in.

Piston Length

61.43 mm

2.419 in.

Piston Ring
Groove Depth
No. 1

3.713-3.882

0.146-0.153 in.

Piston Ring
Groove Depth
No. 2

4.118-4.297

0.162-0.169 in.

Piston Ring
Groove Depth
No. 3

2.818-2.967

0.110-0.116 in.

PISTON PINS

DESCRIPTION

SPECIFICATION

Metric

Standard

Clearance in
Piston

0.004-0.014

0.0001-0.0005

in.

Clearance in
Connecting Rod

0.007-0.018

0.0002-0.0007

in.

Diameter

21.997-22.000

0.8660-0.8661

in.

End Play

0.34-1.44 mm

0.0133-0.0566

in.

Length

65.41-65.85

2.575-2.592 in.

9 - 104

ENGINE 2.4L DOHC TURBO

PL/SRT-4

ENGINE 2.4L DOHC TURBO (Continued)

PISTON RINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Ring Gap-Top
Compression
Ring

0.20-0.40 mm

0.0078-0.0157

in.

Wear Limit

0.8 mm

0.031 in.

Ring Gap-2nd
Compression
Ring

0.20-0.40 mm

0.007-0.015 in.

Wear Limit

0.8 mm

0.031 in.

Ring Gap-Oil
Control Steel
Rails

0.15-0.66 mm

0.005-0.025 in.

Wear Limit

1.0 mm

0.039 in.

Ring Side
Clearance-
Compression
Rings

0.035-0.085

0.001-0.003 in.

Wear Limit

0.10 mm

0.004 in.

Ring Side
Clearance-Oil
Ring Pack

0.027-0.176

0.001-0.006 in.

Ring Width-
Compression
Rings

Top Ring

1.17-1.19 mm

0.0460-0.0468

in.

2nd Ring

1.472-1.49 mm

0.057-0.058 in.

Ring Width-Oil
Ring Pack

2.64-2.89 mm

0.103-0.113 in.

CONNECTING ROD

DESCRIPTION

SPECIFICATION

Metric

Standard

Bearing
Clearance

0.025–0.071

0.0009–0.0027

in.

Wear Limit

0.075 mm

0.003 in.

Bore Diameter-
Piston Pin

22.007-22.015

0.8664-0.8667

in.

Bore Diameter-
Crankshaft End

52.992-53.008

2.0862-2.0869

in.

Side Clearance

0.13–0.38 mm

0.005–0.015 in.

Wear Limit

0.40 mm

0.016 in.

Weight-Total
(Less Bearing)

663.5 grams

23.4 oz.

CRANKSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Connecting Rod
Journal
Diameter

49.984 - 50.000

1.968 - 1.9685

in.

Main Bearing
Journal
Diameter

59.992 - 60.008

2.362 - 2.3625

in.

Journal
Out-of-Round
(Max.)

0.0035 mm

0.0003 in.

Journal Taper
(Max.)

0.007 mm

0.0001 in.

End Play

0.09 - 0.24 mm

0.0035 - 0.0094

in.

Wear Limit

0.38 mm

0.015 in.

Main Bearing
Diametrical
Clearance

0.018 - 0.062

0.0007 - 0.0024

in.

PL/SRT-4

ENGINE 2.4L DOHC TURBO

9 - 105

ENGINE 2.4L DOHC TURBO (Continued)

Content .. 250 251 252 253 ..