Dodge Neon / Neon SRT-4. Manual - part 253

HYDRAULIC LASH ADJUSTER

DESCRIPTION

SPECIFICATION

Metric

Standard

Body Diameter

15.901 - 15.913

mm

0.626 - 0.6264

in.

Plunger Travel
Minimum (Dry)

3.0 mm

0.118 in.

CYLINDER HEAD CAMSHAFT BEARING BORE

DIAMETER

DSECRIPTION

SPECIFICATION

Metric

Standard

Journals No.1 -
6

26.020 - 26.041

mm

1.024 - 1.025 in.

CAMSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Journal
Diameter No.
1–6

25.976 - 25.995

mm

1.022 - 1.023 in.

Bearing
Clearance -
Diametrical

0.025 - 0.065

mm

0.0009 - 0.0025

in.

End Play

0.05 - 0.17 mm

0.0019 - 0.0066

in.

Lift (Zero Lash)

Intake

8.25 mm

(0.324 in.)

Exhaust

6.60 mm

(0.259 mm)

Intake Valve
Timing*

Closes (ABDC)

44.3°

Opens (ATDC)

6.2°

Duration

218°

Exhaust Valve
Timing*

Closes (ATDC)

0.8°

Opens (BBDC)

39.9°

Duration

220.7°

Valve Overlap

5.4°

*
All reading in crankshaft degrees at 0.5 mm (0.019
in.) valve lift.

CYLINDER HEAD

DESCRIPTION

SPECIFICATION

Metric

Standard

Material

Cast Aluminum

Gasket
Thickness
(Compressed)

0.71 mm

0.028 in.

VALVE SEAT

DESCRIPTION

SPECIFICATION

Metric

Standard

Angle

44.5 - 45°

Seat Diameter -
Intake

34.37 - 34.63

mm

1.353 - 1.363 in.

Seat Diameter -
Exhaust

27.06 - 27.32

mm

1.065 - 1.075 in.

Runout (Max.)

0.05 mm

0.002 in.

Valve Seat
Width - Intake
and Exhaust

0.9 - 1.3 mm

0.035 - 0.051 in.

Service Limit -

Intake

2.0 mm

0.079 in.

Service Limit -

Exhaust

2.5 mm

0.098 in.

VALVE GUIDE

DESCRIPTION

SPECIFICATION

Metric

Standard

Diameter I.D.

5.975 - 6.000

mm

0.235 - 0.236 in.

Guide Bore
Diameter

11.0 - 11.02

mm

0.4330 - 0.4338

in.

Guide Height
(spring seat to
guide tip)

13.25 - 13.75

mm

0.521 - 0.541 in.

9 - 106

ENGINE 2.4L DOHC TURBO

PL/SRT-4

ENGINE 2.4L DOHC TURBO (Continued)

VALVES

DESCRIPTION

SPECIFICATION

Metric

Standard

Face Angle -
Intake and
Exhaust

44.5 - 45°

Head Diameter
- Intake

34.67 - 34.93

mm

1.364 - 1.375

in.)

Head Diameter
- Exhaust

28.32 - 28.52

mm

1.114 - 1.122 in.

Valve Length
(Overall)

Intake

112.76 - 113.32

mm

4.439 - 4.461 in.

Exhaust

110.89 - 111.69

mm

4.365 - 4.397 in.

Valve Stem
Diameter

Intake

5.934 - 5.952

mm

0.2337 - 0.2344

in.

Exhaust

5.906 - 5.924

mm

0.2326 - 0.2333

in.

VALVE MARGIN

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

1.2 - 1.7 mm

0.047 - 0.066 in.

Service Limit

0.95 mm

(.0037 in.)

Exhaust

0.985 - 1.315

mm

0.038 - 0.051 in.

Service Limit

1.05 mm

.039 in.

VALVE STEM TIP

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

48.04 mm

1.891 in.

Exhaust

47.99 mm

1.889 in.

VALVE STEM TO GUIDE CLEARANCE

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

0.048 - 0.066

mm

0.0018 - 0.0025

in.

Max. Allowable

0.076 mm

0.003 in.

Service Limit

0.25 mm

0.010 in.

Exhaust

0.0736 - 0.094

mm

0.0029 - 0.0037

in.

Max. Allowable

0.101 mm

0.004 in.

Service Limit

0.25 mm

0.010 in.

VALVE SPRINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Free Length
(Approx.)

49.34 mm

1.943 in.

Nominal Force
(Valve Closed)

311 N @ 38.0

mm

70 lbs. @ 1.496

in.

Nominal Force
(Valve Open)

596 N ± 30.7

N@ 29.25 mm

134 lbs. @

1.152 in.

Installed Height

38.00 mm

1.496 in.

Number of Coils

7.8

Wire Diameter

3.61 mm

0.142 in

OIL PUMP

DESCRIPTION

SPECIFICATION

Metric

Standard

Clearance Over
Rotors (Max.)

0.10 mm

0.004 in.

Cover
Out-of-Flat
(Max.)

0.025 mm

0.001 in.

Inner Rotor
Thickness (Min.)

10.699 mm

0.421 in.

Outer Rotor
Thickness (Min.)

10.699 mm

0.421 in.

Outer Rotor
Clearance
(Max.)

0.039 mm

0.015 in.

Outer Rotor
Diameter (Min.)

85.924 mm

3.383 in.

Tip Clearance
Between Rotors
(Max.)

0.20 mm

0.008 in.

PL/SRT-4

ENGINE 2.4L DOHC TURBO

9 - 107

ENGINE 2.4L DOHC TURBO (Continued)

OIL PRESSURE

DESCRIPTION

SPECIFICATION

Metric

Standard

At Curb Idle
Speed*

25 kPa

4 psi

At 3000 rpm

170 - 550 kPa

25 - 80 psi

CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.

TORQUE

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Balance Shaft Carrier to
Block-Bolts

54

40

-

Balance Shaft Gear
Cover-Double Ended
Fastener

12

-

105

Balance Shaft Sprocket-
Bolt

28

-

250

Balance Shaft Chain
Tensioner-Bolts

12

-

105

Balance Shaft Carrier
Cover-Bolts

12

-

105

Camshaft Sprocket-Bolt

115

85

-

Connecting Rod
Cap-Bolts

27 +

1

⁄

4

turn

20

+

1

⁄

4

turn

-

Crankshaft Main Bearing
Cap/Bedplate

-M8 Bolts

28

-

250

-M11 Bolts

75

55

-

Crankshaft Damper-Bolt

136

100

-

Crankshaft Target Ring

13

-

110

Cylinder Head-Bolts

Refer to Procedure

Cylinder Head Cover-
Bolts

12

-

105

Flex Plate to Crankshaft-
Bolts

95

70

-

Engine Support
Bracket-Bolts

61

45

-

Intake Manifold-Bolts

23

-

200

Intake Manifold Support
Bracket

28

20

-

Oil Cooler Connector Bolt

55

41

-

Oil Filter

14

10

-

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Oil Filter Adapter-Bolts

12

-

105

Oil Jet Fastener

12

-

105

Oil Pan-Bolts

12

-

105

Oil Pan Drain-Plug

28

20

-

Oil Pump to Block-Bolts

28

20

-

Oil Pump Cover
Plate-Bolts

13

-

118

Oil Pump Pick-up
Tube-Bolt

23

-

200

PCV Valve

8

-

70

Spark Plugs

18

13

-

Timing Belt Cover - Front
Upper and Lower-Bolts

6

-

50

Timing Belt Cover - Rear

-M6 Bolts

12

-

105

-M8 Bolts

28

-

250

Timing Belt Idler Pulley

61

45

-

Timing Belt Tensioner
Lock Bolt

25

-

220

Timing Belt Tensioner
Assembly-Bolts

61

45

-

9 - 108

ENGINE 2.4L DOHC TURBO

PL/SRT-4

ENGINE 2.4L DOHC TURBO (Continued)

SPECIAL TOOLS

2.4L ENGINE

Puller 1026

Crankshaft Damper Removal Insert 6827A

Dolly 6135

Cradle 6710

Post Kit Engine Cradle 6848

Clutch Line Disconnect 6638A

Camshaft Sprocket Holder 6847

Camshaft Seal Remover C-4679-A

Camshaft Seal Installer MD-998306

PL/SRT-4

ENGINE 2.4L DOHC TURBO

9 - 109

ENGINE 2.4L DOHC TURBO (Continued)