Dodge Neon / Neon SRT-4. Manual — part 265
INSTALLATION
(1) Replace oil cooler seal (Fig. 120).
(2) Lubricate seal and position oil cooler to oil fil-
ter adapter, aligning notch to tab (Fig. 121).
(3) Install oil cooler connector bolt. Torque connec-
tor bolt to 55 N·m (41 ft. lbs.) (Fig. 119).
(4) Install oil filter.
(5) Connect oil cooler coolant hoses (Fig. 118).
(6) Lower vehicle.
(7) Fill cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
INTAKE MANIFOLD
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 SYSTEM COMPONENTS. SER-
VICE 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 -
Fig. 119 Oil Cooler Connector Bolt
1 - OIL COOLER
2 - CONNECTOR BOLT
Fig. 120 Oil Cooler Seal
1 - OIL COOLER SEAL
Fig. 121 Oil Cooler Alignment
1 - NOTCH
2 - TAB
9 - 154
ENGINE 2.4L DOHC TURBO
PL/SRT-4
OIL COOLER & LINES (Continued)
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
(2) Disconnect negative battery cable.
(3) Remove fuel rail trim cover by pulling straight
off fuel rail studs (Fig. 122).
(4) Disconnect charge air cooler to throttle body
hose (Fig. 123).
(5) Disconnect vacuum hoses from throttle body
and intake manifold.
(6) Disconnect throttle cable from throttle body.
(7) Disconnect Throttle Position Sensor (TPS) and
Idle Air Control (IAC) motor electrical connectors
(8) Remove intake manifold support bracket (Fig.
124).
(9) Disconnect fuel injector electrical connectors
(Fig. 125). Unclip injector wiring harness from fuel
rail.
(10) Disconnect MAP sensor electrical connector
(Fig. 125).
(11) Disconnect the fuel supply line quick connect
at the fuel rail assembly (Refer to 14 - FUEL SYS-
TEM/FUEL
DELIVERY/QUICK
CONNECT
FIT-
TING - STANDARD PROCEDURE) (Fig. 125).
WARNING: WRAP SHOP TOWELS AROUND HOSE
TO CATCH ANY GASOLINE SPILLAGE.
(12) Remove intake manifold fasteners.
(13) Remove intake manifold.
Fig. 122 Fuel Rail Cover
1 - COVER
2 - STUDS
Fig. 123 Charge Air Cooler Hoses
1 - HOSE
2 - HOSE/TUBE - TURBOCHARGER TO CHARGE AIR COOLER
3 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY
4 - CHARGE AIR COOLER
Fig. 124 Intake Manifold Support Bracket
1 - INTAKE MANIFOLD SUPPORT BRACKET
2 - STARTER
PL/SRT-4
ENGINE 2.4L DOHC TURBO
9 - 155
INTAKE MANIFOLD (Continued)
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
(1) Inspect
manifold
for
cracks,
distortion,
or
mounting surface warpage. Replace manifold if nec-
essary.
(2) Inspect manifold gasket for surface damage or
excessive swelling. Replace gaskets as necessary.
INSTALLATION
(1) Clean all gasket surfaces.
(2) Replace intake manifold gasket.
(3) Install intake manifold. Tighten fasteners to 23
N·m (200 in. lbs.).
(4) If removed, install the fuel rail assembly to
intake manifold. Tighten screws to 23 N·m (200 in.
lbs.).
(5) Inspect fuel supply line quick connect fitting
for damage, replace if necessary (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE). Lubricate tube
with clean engine oil. Connect fuel supply line to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position (Fig. 125).
(6) Connect MAP sensor electrical connector (Fig.
125).
(7) Connect fuel injector electrical connectors (Fig.
125). Clip injector wiring harness to fuel rail.
(8) Install
intake
manifold
support
bracket.
Tighten fasteners to 23 N·m (200 in. lbs.) (Fig. 124).
(9) Connect Throttle Position Sensor (TPS) and
Idle Air Control (IAC) motor electrical connectors.
(10) Connect throttle cable to throttle body.
(11) Connect vacuum hoses to throttle body and
intake manifold.
(12) Connect charge air cooler to throttle body
hose (Fig. 123).
(13) Install fuel rail trim cover by pushing it over
fuel rail studs (Fig. 122).
(14) Connect negative cable to battery.
(15) With the DRBIII
t scan tool use ASD Fuel
System Test to pressurize the fuel system to check
for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLD
REMOVAL
NOTE: DO NOT SEPARATE. The exhaust manifold is
serviced as an assembly with the Turbocharger.
(Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - REMOVAL).
INSTALLATION
NOTE: DO NOT SEPARATE. The exhaust manifold is
serviced as an assembly with the Turbocharger.
(Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSTALLATION).
TIMING BELT COVER(S)
REMOVAL
FRONT COVER—UPPER
(1) Remove upper torque strut attaching bolts and
remove strut (Fig. 126).
(2) Remove torque strut bracket from strut tower
(Fig. 126).
(3) Remove torque strut bracket from engine (Fig.
126).
Fig. 125 Electrical and Fuel Line Connections
1 - FUEL SUPPLY LINE CONNECTION
2 - FUEL INJECTOR CONNECTORS
3 - MAP SENSOR
9 - 156
ENGINE 2.4L DOHC TURBO
PL/SRT-4
INTAKE MANIFOLD (Continued)
(4) Remove upper timing belt cover fasteners (Fig.
127) and remove cover.
FRONT COVER—LOWER
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist. Remove right front
wheel.
(3) Remove the acessory drive belt splash shield.
(4) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(5) Remove crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(6) Remove the lower torque strut (Refer to 9 -
ENGINE/ENGINE MOUNTING/TORQUE STRUT -
REMOVAL).
(7) Disconnect exhaust system from manifold.
(8) Disconnect A/C pressure switch at rear of com-
pressor housing.
(9) Lower vehicle and support engine with a jack.
(10) Remove upper torque strut attaching bolts
and remove strut (Fig. 126).
(11) Remove power steering pump and bracket. Set
pump aside. Do not disconnect lines from pump.
(12) With engine properly supported, remove right
engine mount through bolt.
(13) Raise engine with jack until engine support
bracket bolts are accessible (Fig. 128).
(14) Remove engine support bracket (Fig. 128).
(15) Remove
timing
belt
cover
fasteners
and
remove cover (Fig. 127).
Fig. 126 Upper Torque Strut and Bracket
1 - TORQUE STRUT BRACKET
2 - TORQUE STRUT MOUNTING BOLTS
3 - ENGINE BRACKET MOUNTING BOLTS
Fig. 127 Front Timing Belt Covers
1 - UPPER COVER FASTENERS
2 - LOWER COVER FASTENERS
Fig. 128 Engine Support Bracket
1 - ENGINE SUPPORT BRACKET
2 - BOLTS - 61 N·m (45 ft. lbs.)
PL/SRT-4
ENGINE 2.4L DOHC TURBO
9 - 157
TIMING BELT COVER(S) (Continued)
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