Dodge Neon / Neon SRT-4. Manual — part 229
tors to the DRBIII
t. For Special Tool identification,
(Refer to 9 - ENGINE - SPECIAL TOOLS).
(7) Crank
engine
until
maximum
pressure
is
reached on gauge. Record this pressure as #1 cylin-
der pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
STANDARD PROCEDURE
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (excluding spark plug
and camshaft bearing cap attaching threads) can be
repaired. Essentially, this repair consists of drilling
out worn or damaged threads, tapping the hole with
a special Heli-Coil Tap, (or equivalent) and installing
an insert into the tapped hole. This brings the hole
back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect
air
cleaner,
induction
system
and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when
applying
form-in-place
gaskets
to
assure
obtaining the desired results. Do not use form-in-
place gasket material unless specified. Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopar
t
Engine RTV GEN II, Mopar
t ATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPAR
t ENGINE RTV GEN II is used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains
adhesion
and
sealing
properties
when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPAR
t ATF RTV is a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
9 - 10
ENGINE 2.0L SOHC
PL/SRT-4
ENGINE 2.0L SOHC (Continued)
MOPAR
t GASKET MAKER is an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPAR
t BED PLATE SEALANT is a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed
plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPAR
t GASKET SEALANT is a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer
steel
(MLS)
cylinder
head
gaskets.
This
material also will prevent corrosion. Mopar
t Gasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
Mopar
t Gasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
Mopar
t Engine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
Mopar
t Gasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
ENGINE GASKET SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Never use the following to clean gasket surfaces:
• Metal scraper
• Abrasive pad or paper to clean cylinder block
and head
• High speed power tool with an abrasive pad or a
wire brush (Fig. 3)
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
• Solvent or a commercially available gasket
remover
• Plastic or wood scraper (Fig. 3)
• Drill motor with 3M Roloc™ Bristle Disc (white
or yellow) (Fig. 3)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
MEASURING BEARING CLEARANCE USING
PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
(1)
Remove oil film from surface to be checked.
Plastigage is soluble in oil.
Fig. 3 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOC™ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
PL/SRT-4
ENGINE 2.0L SOHC
9 - 11
ENGINE 2.0L SOHC (Continued)
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 4). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap/bed plate bolts of the
bearing being checked to the proper specifications.
(3)
Remove the bearing cap and compare the
width of the flattened Plastigage with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Compare clearance measurements to specs found in
engine specifications (Refer to 9 - ENGINE - SPECI-
FICATIONS). Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install
the
proper
crankshaft
bearings
to
achieve the specified bearing clearances.
ENGINE CORE AND OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 5).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopar
t
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE). Remove fuel line to fuel rail
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(2) Disconnect and remove battery and tray.
(3) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(4) Discharge air conditioning system (if equipped)
(Refer to 24 - HEATING & AIR CONDITIONING -
STANDARD PROCEDURE).
(5) Disconnect the following:
(a) Air intake duct at intake manifold
(b) Throttle cables
(c) Electrical connectors from throttle body
(6) Remove air cleaner housing assembly (Refer to
9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - REMOVAL).
(7) Remove radiator upper hose.
Fig. 4 Plastigage Placed in Lower Shell—Typical
1 - PLASTIGAGE
Fig. 5 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
9 - 12
ENGINE 2.0L SOHC
PL/SRT-4
ENGINE 2.0L SOHC (Continued)
(8) Remove radiator fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL).
(9) Remove radiator lower hose.
(10) Automatic Transmission equipped vehi-
cles:
(a) Using a blade or suitable hose cutter, cut
transaxle oil cooler lines off flush with transmis-
sion fittings. Plug lines and fittings to prevent
debris from entering transaxle or cooler circuit. A
service splice kit will be installed upon reassembly.
(b) Disconnect transmission electrical connec-
tors.
(c) Disconnect transmission shift linkage.
(11) Manual Transmission equipped vehicles:
(a) Using Special Tool 6638A, disconnect clutch
hydraulic line.
(b) Disconnect transmission shift linkage.
(c) Disconnect transmission electrical connectors.
(12) Disconnect engine wiring harness.
(13) Disconnect and remove powertrain control
module (PCM).
(14) Disconnect positive cable from power distribu-
tion center (PDC) and ground wire from vehicle body.
(15) Disconnect the body-to-engine ground wire at
the right side strut tower.
(16) Disconnect heater hoses.
(17) Disconnect vacuum hose from brake booster.
(18) Disconnect coolant reserve/recovery hose.
(19) Remove power steering pump drive belt (Refer
to
7
-
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS - REMOVAL).
(20) Siphon as much fluid as possible from the
power steering fluid reservoir.
(21) Disconnect power steering lines from power
steering pump. Remove the power steering pump/res-
ervoir.
(22) Disconnect lines and remove air conditioning
compressor (if equipped) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/A/C COMPRES-
SOR - REMOVAL).
(23) Hoist vehicle.
(24) Remove front wheels.
(25) Remove accessory drive belt splash shield.
(26) Remove generator drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(27) Drain engine oil.
(28) Remove axle shafts (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - REMOVAL).
(29) Remove
screws
attaching
power
steering
cooler (if equipped) and relocate cooler to provide
engine removal clearance.
(30) Disconnect downstream oxygen sensor connec-
tor.
(31) Disconnect exhaust system from exhaust man-
ifold.
(32) Disconnect exhaust system isolators and move
exhaust rearward.
(33) Remove lower engine torque strut (Refer to 9 -
ENGINE/ENGINE MOUNTING/TORQUE STRUT -
REMOVAL).
(34) Remove generator, lower bracket, and upper
mounting bolt.
(35) Remove
structural
collar,
intake
support
bracket, and dust cover (Fig. 6) (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL).
(36) Automatic Transmission equipped vehi-
cles:
(a) Remove torque converter bolts and mark con-
verter to flex plate orientation for reassembly.
(37) Manual Transmission equipped vehicles:
(a) Remove drive plate to clutch module bolts.
(38) Remove bolt securing power steering line to
engine block. Reposition power steering line to allow
for engine removal.
(39) Lower vehicle.
(40) Raise vehicle enough to allow engine dolly
and cradle, Special Tools 6135 and 6710 to be
installed under vehicle.
(41) Loosen engine support posts to allow move-
ment for positioning onto engine locating holes and
Fig. 6 Manifold Support Bracket, Structural Collar,
and Dust Cover
1 - SUPPORT BRACKET
2 - STRUCTURAL COLLAR
3 - DUST COVER
PL/SRT-4
ENGINE 2.0L SOHC
9 - 13
ENGINE 2.0L SOHC (Continued)
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