Dodge Neon / Neon SRT-4. Manual — part 238
(17) Using a permanent ink or paint marker, iden-
tify cylinder number on each connecting rod cap (Fig.
55).
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(18) Remove all connecting rod bolts and caps.
Care should be taken not to damage the fracture rod
and cap surfaces.
NOTE: Do not reuse connecting rod bolts.
(19)
Remove all bed plate bolts from the engine
block (Fig. 56).
(20) Using a mallet tap the bed plate loose from
the engine block dowel pins.
CAUTION: Do not pry up on one side of the bed
plate. Damage may occur to cylinder block to bed
plate alignment and thrust bearing.
(21) Bedplate should be removed evenly from the
cylinder block dowel pins to prevent damage to the
dowel pins and thrust bearing.
CAUTION: Use extreme care when handling crank-
shaft. Tone wheel damage can occur if crankshaft is
mis-handled.
(22) Lift out crankshaft from cylinder block. Do
not damage the main bearings or journals when
removing the crankshaft.
(23) Remove the target ring mounting screws and
discard.
(24) Remove the target ring from the crankshaft.
INSPECTION
The crankshaft journals should be checked for
excessive wear, taper and scoring (Fig. 57). Limits of
taper or out of round on any crankshaft journals
should be held to 0.025 mm (0.001 in.). Journal
grinding should not exceed 0.305 mm (0.012 in.)
under the standard journal diameter. DO NOT grind
thrust faces of No. 3 main bearing. DO NOT nick
crank pin or bearing fillets. After grinding, remove
rough edges from crankshaft oil holes and clean out
all passages.
CAUTION: With the nodular cast iron crankshafts, it
is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.
Fig. 55 Identify Connecting Rod to Cylinder -
Typical
Fig. 56 Main Bearing Caps/Bed Plate Bolt Removal
Sequence
Fig. 57 Crankshaft Journal Measurements - Typical
9 - 46
ENGINE 2.0L SOHC
PL/SRT-4
CRANKSHAFT (Continued)
INSTALLATION - CRANKSHAFT
CRANKSHAFT MAIN BEARING LOCATION
The crankshaft is supported in five main bearings.
All upper bearing shells in the crankcase have oil
grooves and holes. All lower bearing shells installed
in the (bedplate) main bearing cap are plain. Crank-
shaft end play is controlled by a flanged bearing on
the number three main bearing journal (Fig. 58).
NOTE: The upper and lower main Bearing shells are
Not interchangeable. The lower shell locating tabs
prevent improper installation.
(1) Install the main bearing upper shells with the
lubrication groove and oil hole in the engine block.
Install O-ring into recess in the block (Fig. 59).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
NOTE: If the crankshaft is sent out for machine
work, it must be balenced as an assembly with the
target ring installed.
(3) Clean
crankshaft
and
target
ring
with
MOPAR
t brake parts cleaner and dry with com-
pressed air to ensure that the crankshaft mating sur-
face and target ring mounting holes are free from oil
and lock patch debris.
NOTE: Always use NEW mounting screws whether
installing original or new target ring.
(4) Install NEW mounting screws finger tight
starting with the #1 location. (Fig. 60) Make sure
engagment occurs with the shoulder of the screw and
mounting hole before starting all other screws.
(5) Torque all mounting screws with T30 torx bit
to 13 N·m (110 in-lbs) following the torque sequence.
CAUTION: Use extreme care when handling crank-
shaft. Tone wheel damage can occur if crankshaft is
mis-handled.
CAUTION: Do Not get oil on the bed plate mating
surface. It will affect the ability of the sealer to seal
the bed plate to cylinder block.
Fig. 58 Main Bearing Identification
1 - OIL GROOVES
2 - UPPER BEARINGS
3 - LOWER BEARINGS
4 - OIL HOLES
Fig. 59 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - O-RING
3 - OIL HOLES
Fig. 60 Target Ring Torque Sequence
PL/SRT-4
ENGINE 2.0L SOHC
9 - 47
CRANKSHAFT (Continued)
(6) Oil the bearings and journals and install
crankshaft in engine the block.
CAUTION: Use only Mopar
T
Bed Plate Sealant on
the bed plate or damage may occur to the engine.
(7) Install lower main bearings into main bearing
cap/bed plate. Make certain the bearing tabs are
seated into the bed plate slots and apply oil.
(8) Apply a 1.5 to 2.0 mm (0.059 to 0.078 in.) bead
of Mopar
t Bed Plate Sealant to cylinder block as
shown in (Fig. 61).Install the main bearing/bed plate
into the engine block.
(9) Before installing the bolts oil threads with
clean engine oil, wipe off any excess oil.
(10) Install main bearing bed plate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bed plate contacts the cylin-
der block (Fig. 62).
(11) To ensure correct thrust bearing alignment,
perform the following steps:
• Step 1: Rotate crankshaft until number 4 piston
is at TDC.
• Step 2: Move crankshaft rearward to limits of
travel.
• Step 3: Then, move crankshaft forward to limits
of travel.
• Step 4: Wedge an appropriate tool between the
rear of the cylinder block (NOT BED PLATE) and
the rear crankshaft counterweight. This will hold the
crankshaft in it’s furthest forward position.
• Step 5: Install and tighten bolts (1–10) in
sequence shown in (Fig. 62) to 41 N·m (30 ft. lbs.).
• Step 6: Remove wedge tool used to hold crank-
shaft.
(12) Tighten bolts (1–10) again to 41 N·m (30 ft.
lbs.) in sequence shown in (Fig. 62).
(13) Install main bearing bed plate to engine block
bolts (11–20), with baffle studs in positions 12, 13
and 16 and torque each bolt to 34 N·m (25 ft. lbs.) in
sequence shown in (Fig. 62).
(14) Tighten bolts (1–10) to 81 N·m (60 ft. lbs.) in
sequence shown in (Fig. 62).
(15) Tighten bolts (11–20) again to 34 N·m (25 ft.
lbs.) in sequence shown in (Fig. 62).
(16) After the main bearing bed plate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N·m (50 in. lbs.).
(17) Check crankshaft end play (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT - STAN-
DARD PROCEDURE).
NOTE: The connecting rod cap bolts should not be
reused.
(18) Before installing NEW bolts, lubricate the
threads with clean engine oil.
(19) Install each bolt finger tight then alternately
torque each bolt to assemble the cap properly.
(20) 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.
Fig. 61 Bed plate Sealing
Fig. 62 Main Bearing Caps/Bed Plate Bolt Torque
Sequence
9 - 48
ENGINE 2.0L SOHC
PL/SRT-4
CRANKSHAFT (Continued)
1. Tighten the bolts to 27 N·m (20 ft. lbs.).
2. Tighten the connecting rod bolts an additional
1/4 TURN.
(21) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(22) Install oil pump pick-up tube. Torque fastener
to 23 N·m (200 in. lbs.).
(23) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(24) Install oil filter adapter and oil filter (Fig. 54)
(Refer to 9 - ENGINE/LUBRICATION/OIL FILTER
ADAPTER - INSTALLATION).
(25) Install rear timing belt cover and camshaft
sprocket (Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING BELT COVER(S) - INSTALLATION).
(26) Install front crankshaft oil seal and crank-
shaft sprocket (Refer to 9 - ENGINE/ENGINE
BLOCK/CRANKSHAFT
OIL
SEAL
-
FRONT
-
INSTALLATION).
(27) Install the timing belt tensioner and pulley
bracket (Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING BELT TENSIONER & PULLEY - INSTALLA-
TION).
(28) Install the timing belt, front engine mount
bracket, and front timing belt cover (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT
AND
SPROCKETS - INSTALLATION).
(29) Install crankshaft vibration damper (Refer to
9
-
ENGINE/ENGINE
BLOCK/VIBRATION
DAMPER - INSTALLATION).
(30) Install crankshaft position sensor (Fig. 54).
(31) Install NEW oil filter.
(32) Remove engine from repair stand and position
on Special Tools 6135 and 6710 Engine Dolly and
Cradle. Install safety straps around the engine to
cradle and tighten and lock them into position.
(33) Install the crankshaft rear oil seal (Refer to 9
-
ENGINE/ENGINE
BLOCK/CRANKSHAFT
OIL
SEAL - REAR - INSTALLATION).
(34) Install drive plate/flex plate. Apply Mopar
t
Lock & Seal Adhesive to bolt threads and tighten to
95 N·m (70 ft. lbs.).
(35) Attach transaxle to engine. Tighten attaching
bolts to 101 N·m (75 ft. lbs.).
(36) Install the engine assembly (Refer to 9 -
ENGINE - INSTALLATION).
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Remove the accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL)
(2) Remove
the
crankshaft
vibration
damper.
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(3) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL)
(4) Remove the crankshaft sprocket using Special
Tool 6793 and insert C-4685-C2 (Fig. 63).
(5) Remove the crankshaft sprocket key from
crankshaft (Fig. 64).
CAUTION: Do not nick shaft seal surface or seal
bore.
Fig. 63 Crankshaft Sprocket—Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685–C2
3 - CRANKSHAFT SPROCKET
Fig. 64 Crankshaft Key
1 - CRANKSHAFT KEY
PL/SRT-4
ENGINE 2.0L SOHC
9 - 49
CRANKSHAFT (Continued)
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