Dodge Neon / Neon SRT-4. Manual — part 230
flange on the engine bedplate. Lower vehicle and
position cradle until the engine is resting on support
posts (Fig. 9). 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. 9). Tighten straps and lock them into posi-
tion.
WARNING: Safety straps MUST be used to secure
engine to the dolly fixture.
(43) Raise vehicle enough to see if straps are tight
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 upper engine torque strut (Refer to 9
- ENGINE/ENGINE MOUNTING/TORQUE STRUT -
REMOVAL).
(46)
Remove right and left engine and transaxle
mount through bolts (Fig. 7) and (Fig. 8).
(47) Continue raising vehicle slowly until engine/
transaxle assembly clears engine compartment. It
may be necessary 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. 7) and (Fig. 8). Tighten bolts to 118 N·m (87 ft.
lbs.).
(3) Install upper engine torque strut (Refer to 9 -
ENGINE/ENGINE MOUNTING/TORQUE STRUT -
INSTALLATION).
(4) Remove safety straps from engine/transaxle
assembly. Slowly raise vehicle enough to remove the
engine dolly and cradle.
(5) Raise vehicle on hoist.
(6) Install generator, lower bracket, and adjusting
bolt.
(7) Install axle shafts (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION).
(8) Automatic Transmission equipped vehi-
cles:
(a) Install torque converter bolts.
(9) Manual Transmission equipped vehicles:
(a) Install drive plate to clutch module bolts.
(10) Install bolt securing power steering line to
engine block.
(11) Install screws for power steering cooler (if
equipped).
(12) Install dust shield, intake manifold support
bracket, and structural collar (Fig. 6) (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
INSTALLATION).
(13) Install lower engine torque strut (Refer to 9 -
ENGINE/ENGINE MOUNTING/TORQUE STRUT -
INSTALLATION).
(14) Connect exhaust system isolators and cata-
lytic converter to exhaust manifold. Torque exhaust
fasteners to 28 N·m (250 in. lbs.).
(15) Connect downstream oxygen sensor.
(16) Install A/C compressor and lines (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION).
Fig. 7 Right Mount
1 - THROUGH BOLT
2 - RIGHT ENGINE MOUNT
3 - ENGINE MOUNT BRACKET
Fig. 8 Left Mount Through Bolt
1 - MOUNT BRACKET
2 - BOLT
3 - MOUNT
9 - 14
ENGINE 2.0L SOHC
PL/SRT-4
ENGINE 2.0L SOHC (Continued)
(17) Install accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(18) Ensure oil pan drain plug is tight. Install new
oil filter.
(19) Install accessory drive belt splash shield.
(20) Install front wheels and lower vehicle.
(21) Install power steering pump and reservoir.
Connect power steering lines.
(22) Manual Transmission equipped vehicles:
(a) Connect clutch hydraulic line.
(b) Connect transmission shift linkage.
(c) 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.
(23) Automatic Transmission equipped vehi-
cles:
(a) Connect transmission oil cooler lines using
service splice kit. Refer to instructions provided
with kit.
(b) Connect transmission electrical connectors.
(c) Connect transmission shift linkage.
(24) Connect fuel line (Refer to 14 - FUEL SYS-
TEM/FUEL
DELIVERY/QUICK
CONNECT
FIT-
TING - STANDARD PROCEDURE).
(25) Connect heater hoses.
(26) Connect all ground straps.
(27) Install and connect powertrain control module
(PCM).
(28) Connect engine wiring harness.
(29) Connect lower radiator hose.
(30) Install radiator fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(31) Install upper radiator hose.
(32) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(33) Install battery tray and battery.
(34) Install air cleaner housing assembly and con-
nect intake duct to intake manifold (Refer to 9 -
ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING - INSTALLATION).
(35) Connect all throttle body electrical connectors
and linkage.
(36) Fill engine crankcase with proper oil to cor-
rect level.
(37) Fill power steering fluid reservoir with proper
fluid to correct level.
(38) Evacuate and recharge Air Conditioning sys-
tem (if equipped) (Refer to 24 - HEATING & AIR
CONDITIONING - STANDARD PROCEDURE).
(39) Start engine and run until operating temper-
ature is reached.
(40) Ensure engine is properly positioned by per-
forming torque strut adjustment (Refer to 9 -
ENGINE/ENGINE MOUNTING/TORQUE STRUT -
ADJUSTMENTS).
(41) Adjust transmission linkage, if necessary.
Fig. 9 Positioning Engine Cradle Support Post
1 - SAFETY STRAPS
2 - PLACE REAR POSTS INTO LOCATING HOLES
3 - SPECIAL TOOL 6848
4 - SPECIAL TOOL 6710
5 - SPECIAL TOOL 6135
6 - SAFETY STRAPS
7 - PLACE FRONT POST UNDER BLOCK FLANGE
PL/SRT-4
ENGINE 2.0L SOHC
9 - 15
ENGINE 2.0L SOHC (Continued)
SPECIFICATIONS
2.0L SOHC ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Metric
Standard
Type
In-Line OHV, SOHC
Number of
Cylinders
4
Displacement
2.0 Liters
122 cu. in.
Bore
87.5 mm
3.445 in.
Stroke
83.0 mm
3.268 in.
Compression
Ratio
9.3:1
Firing Order
1-3-4-2
Compression
Pressure
1172-1551 kPa
170-225 psi
Max. Variation
Between
Cylinders
25%
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
87.456-87.474
mm
3.4432-3.4439
in.
Clearance @
17.5 mm (11/16
in.) from bottom
of skirt
0.018-0.050
mm
0.0007-0.0020
in.
Weight
320-329 grams
11.28-11.60 oz.
Land Clearance
(Diametrical)
0.758-0.790
mm
0.0299-0.0312
in.
Piston Length
55.8 mm
2.197 in.
Piston Ring
Groove Depth
No. 1
3.989-4.188
mm
0.157-0.165 in.
Piston Ring
Groove Depth
No. 2
4.462-4.661
mm
0.176-0.184 in.
Piston Ring
Groove Depth
No. 3
3.847-4.131
mm
0.151-0.163 in.
PISTON PINS
DESCRIPTION
SPECIFICATION
Metric
Standard
Clearance in
Piston
0.008-0.015
mm
0.0003-0.0006
in.
Clearance in
Connecting Rod
Interference
Diameter
21.000-21.003
mm
0.8268-0.8269
in.
End Play
None
Length
74.75-75.25
mm
2.943-2.963 in.
9 - 16
ENGINE 2.0L SOHC
PL/SRT-4
ENGINE 2.0L SOHC (Continued)
PISTON RINGS
DESCRIPTION
SPECIFICATION
Metric
Standard
Ring Gap-Top
Compression
Ring
0.23-0.52 mm
0.009-0.020 in.
Wear Limit
0.8 mm
0.031 in.
Ring Gap-2nd
Compression
Ring
0.49-0.78 mm
0.019-0.031 in.
Wear Limit
1.0 mm
0.039 in.
Ring Gap-Oil
Control Steel
Rails
0.23-0.66 mm
0.009-0.026 in.
Wear Limit
1.0 mm
0.039 in.
Ring Side
Clearance-
Compression
Rings
0.025-0.065
mm
0.0010-0.0026
in.
Wear Limit
0.10 mm
0.004 in.
Ring Side
Clearance-Oil
Ring Pack
0.004-0.178
mm
0.0002-0.0070
in.
Ring Width-
Compression
Rings
1.17-1.19 mm
0.046-0.047 in.
Ring Width-Oil
Ring Pack
2.854-3.008
mm
0.1124-0.1184
in.
CONNECTING ROD
DESCRIPTION
SPECIFICATION
Metric
Standard
Bearing
Clearance
0.026-0.059
mm
0.001-0.0023 in.
Wear Limit
0.075 mm
0.003 in.
Bore Diameter-
Piston Pin
20.96-20.98
mm
0.8252-0.8260
in.
Bore Diameter-
Crankshaft End
50.991-51.005
mm
2.0075-2.0081
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)
548.8 grams
19.36 oz.
CRANKSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Connecting Rod
Journal
Diameter
47.9924-
48.0076 mm
1.8894-1.8900
in.
Main Bearing
Journal
Diameter
51.9924-
52.0076 mm
2.0469-2.0475
in.
Journal
Out-of-Round
(Max.)
0.0035 mm
0.0001 in.
Journal Taper
(Max.)
0.0038 mm
0.0001 in.
End Play
0.09-0.24 mm
0.0035-0.0094
in.
Wear Limit
0.37 mm
0.015 in.
Main Bearing
Diametrical
Clearance
0.022-0.062
mm
0.0008-0.0024
in.
ROCKER ARM SHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Rocker Arm
Shaft Diameter
19.966-19.984
mm
0.7861-0.7868
in.
ROCKER ARM SHAFT RETAINERS
DESCRIPTION
SPECIFICATION
Metric
Standard
Intake-Width
28.43-28.49
mm
1.1193-1.1217
in.
Exhaust-Width 1
and 5
29015-29.25
mm
1.1477-1.1516
in.
Exhaust-Width
2,3, and 4
40.40-40.50
mm
1.5906-1.5945
in.
PL/SRT-4
ENGINE 2.0L SOHC
9 - 17
ENGINE 2.0L SOHC (Continued)
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