Dodge Neon / Neon SRT-4. Manual — part 240
NOTE: Piston and rods are serviced as an assem-
bly.
(10) Repeat procedure for each piston and connect-
ing rod assembly.
(11) Remove piston rings (Refer to 9 - ENGINE/
ENGINE BLOCK/PISTON RINGS - REMOVAL).
INSTALLATION
(1) Install piston rings on piston (Refer to 9 -
ENGINE/ENGINE
BLOCK/PISTON
RINGS
-
INSTALLATION).
(2) Before installing pistons and connecting rod
assemblies into the bore, ensure the compression ring
gaps are staggered, and neither is in line with the oil
ring rail gap (Fig. 84).
(3) Before installing the ring compressor, ensure
the oil ring expander ends are butted and the rail
gaps are located as shown in (Fig. 84). As viewed
from top.
(4) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 77). Be sure position of rings does not
change during this operation.
(5) The weight stamp designation L or H will be in
the front half of the piston should face toward the
front of the engine (Fig. 74).
(6) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Lubri-
cate connecting rod journal with clean engine oil.
(7) Install connecting rod upper bearing half into
connecting rod. Install Special Tool 8189, connecting
rod guides onto connecting rod (Fig. 76).
(8) Insert rod and piston assembly into cylinder
bore and carefully guide rod over the crankshaft jour-
nal.
(9) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(10) Remove Special Tool 8189, connecting rod
guides.
NOTE: The connecting rod cap bolts should not be
reused.
(11) Before installing the NEW bolts, the threads
should be coated with clean engine oil.
(12) Install connecting rod lower bearing half into
connecting rod cap. Install connecting rod cap.
(13) Install each bolt finger tight then alternately
torque each bolt to assemble the cap properly.
(14) 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.
(15) Using a feeler gauge, check connecting rod
side clearance (Fig. 78). (Refer to 9 - ENGINE -
SPECIFICATIONS) for connecting rod side clearance.
(16) Install
the
cylinder
head
(Refer
to
9
-
ENGINE/CYLINDER HEAD - INSTALLATION).
(17) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
Fig. 76 Connecting Rod Guides—Typical
1 - SPECIAL TOOL 8189 CONNECTING ROD GUIDES
Fig. 77 Installing Piston
9 - 54
ENGINE 2.0L SOHC
PL/SRT-4
PISTON & CONNECTING ROD (Continued)
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. 78). 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
positioned below normal ring travel in the cylinder
bore. Check gap with feeler gauge (Fig. 79). For pis-
ton ring specifications (Refer to 9 - ENGINE - SPEC-
IFICATIONS).
(2) Check piston ring to groove side clearance (Fig.
80). For piston ring specifications (Refer to 9 -
ENGINE - SPECIFICATIONS).
REMOVAL
(1) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 81).
(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.
Fig. 78 Connecting Rod Side Clearance - Typical
Fig. 79 Piston Ring Gap
1 - FEELER GAUGE
Fig. 80 Piston Ring Side Clearance
1 - FEELER GAUGE
PL/SRT-4
ENGINE 2.0L SOHC
9 - 55
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. 82).
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. 82).
(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. 83).
(3) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 82).
(4) Position piston ring end gaps as shown in (Fig.
84).
(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.
Fig. 81 Piston Rings—Removing and Installing
Fig. 82 Piston Ring Installation
1 - NO. 1 PISTON RING
2 - NO. 2 PISTON RING
3 - SIDE RAIL
4 - OIL RING
5 - SPACER EXPANDER
Fig. 83 Installing Side Rail
1 - SIDE RAIL END
Fig. 84 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
9 - 56
ENGINE 2.0L SOHC
PL/SRT-4
PISTON RINGS (Continued)
STRUCTURAL COLLAR
REMOVAL
(1) Raise vehicle on hoist.
NOTE: To remove transaxle dust cover, the front
bending strut must be removed.
(2) Remove structural collar from oil pan to trans-
axle (Fig. 85).
INSTALLATION
CAUTION: The torque procedure for the structural
collar must be followed, as damage to oil pan or
collar could occur.
(1) Install the structural collar (Fig. 85) using the
following 3 step torque sequence:
• Step 1: Install the collar to oil pan bolts and
tighten to 3 N·m (30 in. lbs.).
• Step 2: Install collar to transaxle bolts and
tighten to 108 N·m (80 ft. lbs.).
• Step 3: Final torque the collar to oil pan bolts to
54 N·m (40 ft. lbs.).
(2) Lower vehicle.
FLEX PLATE
REMOVAL
(1) Remove the transaxle. Refer to 21 - TRANS-
AXLE for procedure.
(2) Remove the flex plate attaching bolts (Fig. 86).
(3) Remove the flex plate (Fig. 86).
INSTALLATION
(1) Position the drive plate on crankshaft (Fig. 86).
(2) Apply Mopar
t Lock & Seal Adhesive to flex
plate bolt threads.
(3) Install the flex plate bolts and tighten to 95
N·m (70 ft. lbs.) (Fig. 86).
(4) Install the transaxle. Refer to 21 - TRANS-
AXLE for procedure.
Fig. 85 Structural Collar - Removal/Installation
1 - OIL PAN
2 - STRUCTURAL COLLAR
Fig. 86 Flex Plate
1 - ADAPTOR PLATE
2 - BOLT
3 - BOLT (QTY. 8)
4 - FLEX PLATE
PL/SRT-4
ENGINE 2.0L SOHC
9 - 57
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