Dodge Neon / Neon SRT-4. Manual — part 245
(5)
Slide outer rotor into pump housing, press to
one side with fingers and measure clearance between
rotor and housing (Fig. 122). 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 clear-
ance between inner and outer rotors (Fig. 123) is
0.203 mm (0.008 in.) or more, replace both rotors.
(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 (Fig. 124). 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 spec-
ifications.
(10) If oil pressure is low and pump is within spec-
ifications, 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 pres-
sure relief valve or other reasons for oil pressure
loss.
ASSEMBLY
(1) Install oil pump rotors (Fig. 118).
(2) Install oil pump cover and screws (Fig. 118).
Tighten screws to 12 N·m (105 in. lbs.).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 117) or serious damage
may occur.
(3) Install spring and relief valve (Fig. 117).
(4) Install threaded plug and gasket to the oil
pump (Fig. 117). Tighten plug to 41 N·m (30 ft. lbs.).
Fig. 122 Measuring Outer Rotor Clearance in
Housing
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 123 Measuring Clearance Between Rotors
1 - FEELER GAUGE
2 - INNER ROTOR
3 - OUTER ROTOR
Fig. 124 Measuring Clearance Over Rotors
1 - FEELER GAUGE
2 - STRAIGHT EDGE
9 - 74
ENGINE 2.0L SOHC
PL/SRT-4
OIL PUMP (Continued)
INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.
(2) Apply Mopar
t Gasket Maker to oil pump as
shown in (Fig. 125). Install o-ring into oil pump body
discharge passage.
(3) Prime oil pump before installation.
(4) Align oil pump rotor flats with flats on crank-
shaft as you install the oil pump to the block.
NOTE: Front crankshaft seal MUST be out of pump
to align, or damage may result.
(5) Torque all oil pump attaching bolts to 28 N·m
(250 in. lbs.).
(6) Install new front crankshaft seal using Special
Tool 6780 (Fig. 126).
NOTE: Make sure the word “front” on the crank-
shaft sprocket is facing outward.
CAUTION: Use of Special Tool 6792 is required to
install the crankshaft sprocket to the proper depth.
Failure to use this tool will cause improper timing
belt tracking.
(7) Install crankshaft sprocket, using Special Tool
6792 (Fig. 127).
(8) Install oil pick-up tube and oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL
PAN
-
INSTALLA-
TION).
(9) Install timing belt rear cover and camshaft
sprocket (Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING BELT COVER(S) - INSTALLATION).
(10) Install timing belt tensioner assembly (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT
TENSIONER ASSEMBLY - INSTALLATION).
(11) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(12) Install front timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(13) Fill engine crankcase with proper oil to cor-
rect level.
(14) Connect negative cable to battery.
Fig. 125 Oil Pump Sealing
1 - APPLY GASKET MAKER TO OIL PUMP BODY FLANGE
2 - O-RING
Fig. 126 Front Crankshaft Seal—Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780–1
4 - INSTALLER
Fig. 127 Crankshaft Sprocket—Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
PL/SRT-4
ENGINE 2.0L SOHC
9 - 75
OIL PUMP (Continued)
OIL FILTER ADAPTER
REMOVAL
(1) Remove the oil filter (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - REMOVAL).
(2) Remove assembly by unscrewing adaptor fit-
ting (Fig. 128).
(3) Remove O-ring seal.
INSTALLATION
(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.) (Fig. 128).
(3) Install oil filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - INSTALLATION).
INTAKE MANIFOLD
DESCRIPTION
The intake manifold is a molded plastic composi-
tion, attached to the cylinder head with fasteners.
The manifold is a long branch design to enhance low
and mid-range torque.
OPERATION
The intake manifold delivers air to the combustion
chambers. This air allows the fuel delivered by the
fuel injectors to ignite when the spark plugs fire.
DIAGNOSIS AND TESTING
INTAKE MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM’S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Perform fuel system pressure release procedure
before attempting any repairs (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
(2) Disconnect negative cable from battery.
(3) Remove the inlet air duct from intake manifold
to throttle body.
WARNING: WRAP SHOP TOWELS AROUND FUEL
HOSE TO CATCH ANY GASOLINE SPILLAGE
(4) Disconnect fuel supply line quick connect at the
fuel tube assembly (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/QUICK CONNECT FITTING -
STANDARD PROCEDURE).
(5) Remove fuel rail assembly attaching screws
and remove fuel rail assembly from engine. Cover
injector holes with suitable covering.
Fig. 128 Engine Oil Filter Adapter to Engine Block
1 - O-RING
2 - LOCATING ROLL PIN
3 - OIL FILTER ADAPTER
9 - 76
ENGINE 2.0L SOHC
PL/SRT-4
CAUTION: Do not set fuel injectors on their tips,
damage may occur to the injectors
(6) Disconnect brake booster hose (Fig. 129) and
PCV hose (Fig. 130) from intake manifold.
(7) Disconnect Manifold Absolute Pressure (MAP)
sensor electrical connector (Fig. 131).
(8) Disconnect knock sensor electrical connector
(Fig. 132).
Fig. 129 Brake Booster Hose
Fig. 130 PCV Hose
Fig. 131 MAP Sensor
Fig. 132 Knock Sensor
1 - KNOCK SENSOR
2 - STARTER MOTOR
PL/SRT-4
ENGINE 2.0L SOHC
9 - 77
INTAKE MANIFOLD (Continued)
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