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
to
9
-
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
4
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
mm
3.4424-3.4431
in.
Clearance @ 22
mm (0.866 in.)
from bottom of
skirt
0.046-0.064
mm
0.0018-0.0025
in.
Weight
345-355 grams
12.17-12.52 oz.
Land Clearance
(Diametrical)
0.556-0.674
mm
0.021-0.027 in.
Piston Length
61.43 mm
2.419 in.
Piston Ring
Groove Depth
No. 1
3.713-3.882
mm
0.146-0.153 in.
Piston Ring
Groove Depth
No. 2
4.118-4.297
mm
0.162-0.169 in.
Piston Ring
Groove Depth
No. 3
2.818-2.967
mm
0.110-0.116 in.
PISTON PINS
DESCRIPTION
SPECIFICATION
Metric
Standard
Clearance in
Piston
0.004-0.014
mm
0.0001-0.0005
in.
Clearance in
Connecting Rod
0.007-0.018
mm
0.0002-0.0007
in.
Diameter
21.997-22.000
mm
0.8660-0.8661
in.
End Play
0.34-1.44 mm
0.0133-0.0566
in.
Length
65.41-65.85
mm
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
mm
0.001-0.003 in.
Wear Limit
0.10 mm
0.004 in.
Ring Side
Clearance-Oil
Ring Pack
0.027-0.176
mm
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
mm
0.0009–0.0027
in.
Wear Limit
0.075 mm
0.003 in.
Bore Diameter-
Piston Pin
22.007-22.015
mm
0.8664-0.8667
in.
Bore Diameter-
Crankshaft End
52.992-53.008
mm
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
mm
1.968 - 1.9685
in.
Main Bearing
Journal
Diameter
59.992 - 60.008
mm
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
mm
0.0007 - 0.0024
in.
PL/SRT-4
ENGINE 2.4L DOHC TURBO
9 - 105
ENGINE 2.4L DOHC TURBO (Continued)
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