Dodge Neon / Neon SRT-4. Manual — part 261

2. Tighten the connecting rod bolts an additional

1/4 TURN.

(14) Using a feeler gauge, check connecting rod

side clearance (Fig. 79). (Refer to 9 - ENGINE -
SPECIFICATIONS) for connecting rod side clearance.

(15) Install Balance Shaft Carrier Assembly (Refer

to 9 - ENGINE/VALVE TIMING/BALANCE SHAFT
CARRIER - INSTALLATION).

(16) Install oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - INSTALLATION).

(17) Install cylinder head (Refer to 9 - ENGINE/

CYLINDER HEAD - INSTALLATION).

CONNECTING ROD BEARINGS

STANDARD PROCEDURE

CONNECTING ROD - FITTING

(1) For measuring connecting rod bearing clear-

ance procedure and use of Plastigage (Refer to 9 -
ENGINE - STANDARD PROCEDURE). For bearing
clearance refer to Engine Specifications. (Refer to 9 -
ENGINE - SPECIFICATIONS)

NOTE: The rod bearing bolts should not be reused.

(2) Before installing the NEW bolts the threads

should be oiled with clean engine oil.

(3) Install each bolt finger tight then alternately

torque each bolt to assemble the cap properly.

(4) Tighten the connecting rod bolts using the 2

step torque-turn method. Tighten according to the
following values:

CAUTION: Do not use a torque wrench for the sec-
ond step.

1. Tighten the bolts to 27 N·m (20 ft. lbs.).
2. Tighten the connecting rod bolts an additional

1/4 TURN.

(5) Using a feeler gauge, check connecting rod side

clearance (Fig. 80). Refer to clearance specifications
(Refer to 9 - ENGINE - SPECIFICATIONS).

PISTON RINGS

STANDARD PROCEDURE

PISTON RING - FITTING

(1) Wipe cylinder bore clean. Insert ring and push

down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 inch) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 81).
Refer to Engine Specifications.

Fig. 79 Checking Connecting Rod Side Clearance -

Typical

Fig. 80 Connecting Rod Side Clearance - Typical

Fig. 81 Piston Ring Gap

1 - FEELER GAUGE

9 - 138

ENGINE 2.4L DOHC TURBO

PL/SRT-4

PISTON & CONNECTING ROD (Continued)

(2) Check piston ring to groove side clearance (Fig.

82). Refer to Engine Specifications.

REMOVAL

(1) Using a suitable ring expander, remove upper

and intermediate piston rings (Fig. 83).

(2) Remove the upper oil ring side rail, lower oil

ring side rail and then oil ring expander from piston.

(3) Clean ring grooves of any carbon deposits.

INSTALLATION

NOTE: The identification mark on face of upper and
intermediate piston rings must point toward top of
piston.

Install rings with manufacturers identification

mark facing up, to the top of the piston (Fig. 84).

CAUTION: Install piston rings in the following
order:

1. Oil ring expander.
2. Upper oil ring side rail.
3. Lower oil ring side rail.
4. No. 2 Intermediate piston ring.
5. No. 1 Upper piston ring.
(1) Install oil ring expander (Fig. 84).

Fig. 82 Piston Ring Side Clearance

1 - FEELER GAUGE

Fig. 83 Piston Rings—Removing and Installing

Fig. 84 Piston Ring Installation

1 - NO. 1 PISTON RING
2 - NO. 2 PISTON RING
3 - SIDE RAIL
4 - OIL RING
5 - SPACER EXPANDER

PL/SRT-4

ENGINE 2.4L DOHC TURBO

9 - 139

PISTON RINGS (Continued)

(2) Install upper side rail first and then the lower

side rail. Install the side rails by placing one end
between the piston ring groove and the oil ring
expander. Hold end firmly and press down the por-
tion to be installed until side rail is in position. Do
not use a piston ring expander (Fig. 85).

(3) Install No. 2 piston ring and then No. 1 piston

ring (Fig. 84).

(4) Position piston ring end gaps as shown in (Fig.

86).

(5) Position oil ring expander gap at least 45° from

the side rail gaps but not on the piston pin center or
on the thrust direction. Staggering ring gap is impor-
tant for oil control.

STRUCTURAL COLLAR

REMOVAL

STRUCTURAL COLLAR

(1) Raise vehicle on hoist.
(2) Remove bolts attaching bending strut to engine

and transaxle (Fig. 87). Remove strut.

(3) Remove bolts attaching collar and clutch slave

cylinder to transaxle (Fig. 87).

(4) Remove remaining bolts attaching collar to oil

pan and transaxle (Fig. 87). Remove collar.

INSTALLATION

STRUCTURAL COLLAR

CAUTION: Torque procedure for the structural collar
and bending strut must be followed or damage
could occur to oil pan, collar, and/or bending strut.

(1) Perform the following steps for installing struc-

tural collar and bending strut. Refer to (Fig. 87):

• Step 1: Place collar into position between trans-

axle and oil pan. Install collar to transaxle bolt (1),
hand start only.

Fig. 85 Installing Side Rail

1 - SIDE RAIL END

Fig. 86 Piston Ring End Gap Position

1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP

Fig. 87 Structural Collar and Bending Strut -

(Manual Transaxle Equipped)

1–5 – BOLT TIGHTENING SEQUENCE
6 – HYDRAULIC CLUTCH SLAVE CYLINDER
7 – TRANSAXLE
8 – POWER STEERING HOSE
9 – COLLAR

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ENGINE 2.4L DOHC TURBO

PL/SRT-4

PISTON RINGS (Continued)

• Step 2: Position power steering hose support

bracket (Fig. 87) and install collar to oil pan bolt (2),
hand tight only.

• Step 3: Position clutch slave cylinder into

mounting position and install bolts (3) and (4) hand
tight only.

• Step 4: Position power steering hose support

bracket and install the remaining collar to oil pan
bolt (5) hand tight only.

• Step 5: Final torque all bolts in sequence shown

in (Fig. 87) to the following torque values:

• Bolt (1) to 101 N·m (75 ft. lbs.)

• Bolts (2) and (5) to 61 N·m (45 ft. lbs.)

• Bolts (3) and (4) to 28 N·m (20 ft. lbs.)

(2) Lower vehicle.

VIBRATION DAMPER

REMOVAL

(1) Remove accessory drive belts (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

-

REMOVAL).

(2) Remove crankshaft damper bolt.
(3) Remove damper by using Special Tool 1026 and

Insert 6827A (Fig. 88).

INSTALLATION

(1) Install crankshaft damper using Special Tool

6792 (M12 1.75 x 150 mm bolt, washer, thrust bear-
ing and nut).

NOTE: Lubricate the threads of the M12 1.75 x 150
mm bolt using Mopar

T

Nickel Anti-seize Compound

or equivalent, before beginning to press the damper
on.

(2) Apply Mopar

t Lock & Seal Adhesive (Medium

Strength Threadlocker) to crankshaft damper bolt
and tighten to 136 N·m (100 ft. lbs.) (Fig. 89).

(3) Install accessory drive belts (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

-

INSTALLATION).

ENGINE MOUNTING

DESCRIPTION

The engine mounting system consists of a four-

point system utilizing two load-carrying mounts and
two torque struts. The load-carrying mounts are
located on each frame rail. The two torque control-
ling struts are attached at the front of the engine,
straddling the right side load-carrying mount. The
upper strut connects to the suspension strut tower
and the lower to the suspension crossmember.

Fig. 88 Crankshaft Damper—Removal

1 - SPECIAL TOOL 1026 3 - JAW PULLER
2 - SPECIAL TOOL 6827A INSERT

Fig. 89 Crankshaft Damper—Installation

1 - SPECIAL TOOL 6792

PL/SRT-4

ENGINE 2.4L DOHC TURBO

9 - 141

STRUCTURAL COLLAR (Continued)