Dodge Neon / Neon SRT-4. Manual — part 272
INSTALLATION - LINES AND HOSES
NOTE: For line and hose location refer to (Fig. 27).
COOLANT SUPPLY LINE
(1) If brass fitting was removed from engine block,
apply thread sealer to threads and install in engine
block. Torque brass fitting to 41 N·m (30 ft. lbs.).
(2) Position coolant supply line to mounting loca-
tion.
(3) Install NEW washers on banjo fitting of cool-
ant supply line (Fig. 24). Hand start banjo bolt.
(4) Hand start flared fitting of coolant supply line.
(5) Torque banjo fitting bolt to 37 N·m (27 ft. lbs.)
(Fig. 26).
(6) Torque flared fitting to 31 N·m (23 ft. lbs.) (Fig.
24).
(7) Lower vehicle.
(8) Fill cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
COOLANT RETURN LINE
(1) Position coolant return line to mounting loca-
tion.
(2) Install NEW washers on banjo fitting of cool-
ant return line (Fig. 26). Hand start banjo bolt.
(3) Install hose onto heater tube. Install hose
clamp (Fig. 23).
(4) Torque banjo fitting bolt to 37 N·m (27 ft. lbs.)
(Fig. 26).
(5) Install fastener securing coolant return line
bracket to cylinder head cover stud (Fig. 23).
(6) Install turbocharger clean air hose (Fig. 15).
(7) Tighten hose clamps to 1.7 N·m (15 in. lbs.).
(8) Fill cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
OIL SUPPLY LINE
(1) If brass fitting was removed from engine block,
apply thread sealer to threads and install. Torque
brass fitting to 41 N·m (30 ft. lbs.).
(2) Position oil supply line to mounting location.
(3) Install NEW washers on banjo fitting of oil
supply line (Fig. 26). Hand start banjo bolt at turbo-
charger (Fig. 25).
(4) Raise vehicle on hoist.
(5) Hand start flared fitting at engine block (Fig.
25).
(6) Torque flared fitting to 31 N·m (23 ft. lbs.) (Fig.
25).
(7) Install elbow support bracket (Fig. 23).
(8) Lower vehicle.
(9) Torque banjo fitting bolt to 37 N·m (27 ft. lbs.)
(Fig. 26).
OIL RETURN LINE
(1) Clean gasket surfaces.
(2) Install new gasket.
(3) Install oil return line hose over crankcase nip-
ple (Fig. 20).
(4) Install the two fasteners securing the oil return
line to the turbocharger. Torque fasteners to 12 N·m
(105 in. lbs.).
(5) Install and tighten hose clamp for oil return
line hose.
(6) Lower vehicle.
Fig. 25 Oil Supply Line - Turbocharger Fitting
1 - OIL SUPPLY LINE
2 - FLARED FITTING - 31 N·m (23 ft. lbs.)
3 - BRASS FITTING - 41 N·m (30 ft. lbs.)
Fig. 26 Banjo Bolt and Washers
1 - BANJO BOLT
2 - WASHERS
11 - 14
EXHAUST SYSTEM AND TURBOCHARGER
PL/SRT-4
LINES AND HOSES (Continued)
SOLENOIDS AND VACUUM
HARNESS
DESCRIPTION
NOTE: Refer to (Fig. 27) and (Fig. 28) for vacuum
harness routing and component location.
Turbocharged vehicles are equipped with three
solenoids that are PCM controlled. They are mounted
to the air cleaner housing cover. A vacuum harness
connects the solenoids to their respective component.
• Wastegate Actuator Solenoid
• Surge Valve Actuator Solenoid
• Throttle Inlet Pressure (TIP) Solenoid
Fig. 27 Vacuum Harness Schematic
PL/SRT-4
EXHAUST SYSTEM AND TURBOCHARGER
11 - 15
REMOVAL
NOTE: For specific solenoid location, refer to (Fig.
28).
(1) Remove solenoid mounting bracket screws (Fig.
28).
(2) Disconnect solenoid electrical connector.
(3) Disconnect vacuum harness connector from
solenoid.
(4) Push on solenoid lock tab and slide solenoid off
bracket (Fig. 29).
INSTALLATION
(1) Slide solenoid onto mounting bracket until lock
tab engages (Fig. 29).
(2) Connect vacuum harness connector to solenoid.
(3) Connect solenoid electrical connector.
(4) Install
screws
securing
solenoid
mounting
bracket to air cleaner housing (Fig. 28).
Fig. 28 Turbocharger Solenoids and Mounting
Bracket
1 - TIP SOLENOID
2 - SURGE VALVE ACTUATOR SOLENOID
3 - WASTEGATE ACTUATOR SOLENOID
4 - BRACKET MOUNTING SCREWS
Fig. 29 Solenoid Lock Tab
1 - LOCK TAB
11 - 16
EXHAUST SYSTEM AND TURBOCHARGER
PL/SRT-4
SOLENOIDS AND VACUUM HARNESS (Continued)
EXHAUST SYSTEM
TABLE OF CONTENTS
page
page
EXHAUST SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM RESTRICTION CHECK . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . 21
CATALYTIC CONVERTER
. . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . 23
HEAT SHIELDS
. . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . 25
INTERMEDIATE PIPE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . 25
MUFFLER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . 27
EXHAUST SYSTEM
DESCRIPTION
The exhaust system consists of an under floor cat-
alytic converter, intermediate pipe, and a muffler
with tailpipe (Fig. 1).
Fig. 1 Exhaust System
1 - CATALYTIC CONVERTER
4 - MUFFLER
2 - EXHAUST INTERMEDIATE PIPE
5 - BAND CLAMP
3 - ISOLATORS
6 - BAND CLAMP
PL/SRT-4
EXHAUST SYSTEM
11 - 17
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