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 Post subject: Misc info: Torque Specs, Fluid Capacities and More.(3/8/06)
PostPosted: Fri Mar 03, 2006 3:08 pm 
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This is just the beginning of what I hope will be a complete list of all torque specs, fluid capacities and other misc info for the 1st gen Neon.

Code:
Fluid Capacities
----------------

Fuel Tank
        12.5 Gallons (96-99 Plastic)
        11.7 Gallons (95 Metal)

Engine Oil With Filter Change
        4.5 Quarts

Engine Oil Without Filter Change
        4.0 Quarts

Cooling System
        6.5 Quarts

Automatic Tranmission
        31 TH   8.9 Quarts

Manual Transmission
        NV T350 1.9-2.2 L

Power Steering
        .95 L

Misc
----

Spark Plug Gap
                0.033 to 0.038  (Champion RC9YC)

Lighting - Exterior
-------------------

Back-up Light           3157
3rd Brake Light         921
Fog Lights              881
Headlights              9007
License Plate Light     168
Park/Turn Signals       3157NA
Tail/Stop/Turn signal   3157
Side Marker Lights      168

Lighting - Inerior
------------------

HVAC lights             203
Ash Tray                161
Cigar Lighter           203
Dome Light              578
Gear Selector (ATX)     161
Glove Box               194
Ignition lock           161
Instrument Cluster      PC194
Trunk Light             912
Underhood light    Belt Tension
------------

PS & A/C
          Gauge         Torque
        New 135 lb      121 N.m (90 ft. lbs)
        Used 100 lb     81 N.m (60 ft. lbs)

Generator
        New 135 lb      121 N.m (90 ft. lbs)
        Used 100 lb     81 N.m (60 ft.lbs)

A/C Condensor to Radiator
        Screws
                7.2 N.m (65 in. lbs)
Fan Module to Radiator
        Screws
                7.2 N.m (65 in. lbs)
Fan Motor to Shroud (A/C Equipped)
        Screws
                3.8 N.m (34 in. lbs)
Fan Motor to Shroud (Non A/C)
        Screws
                2.3 N.m (20 in. lbs)
Radiator (Cooling Module) to Body
        Screws
                10 N.m (90 in. lbs)
Thermostat Housing/Water Outlet Connector
        Screws
                12 N.m (105 in. lbs)
Upper Radiator Crossmember
        Bolts
                28 N.m (250 in. lbs)
Water Pump to Engine Block
        Bolts
                12 N.m (105 in. lbs)
Water Pump Inlet Tube to Engine Block
        Blots
                12 N.m (105 in. lbs)

Torque Specs
------------

A/C Condensor to Radiator
                7.2 N.m (65 in. lbs)
Fan Module to Radiator
                7.2 N.m (65 in. lbs)
Fan Motor to Shroud Retaining Screws
                wA/C 3.8 N.m (34 in. lbs)
                woA/C 2.3 N.m (20 in. lbs)

Radiator to Body Screws
                7.2 N.m (65 in. lbs)
Thermostat housing/engine outlet connector screws
                12 N.m (105 in. lbs)
Upper Radiator crossmember bolts
                28 N.m (250 in. lbs)
Water Pump to Engine Block Mouting Bolts
                12 N.m (105 in. lbs)
Water Pump Inlet Tube to Engine Block Mouting Screws
                12 N.m (105 in. lbs)

Accelerator Pedal to Dash Nuts
                12 N.m (105 in. lbs)
Fuel Pump Module Locknut
                55 N.m  (40 ft. lbs)
Fuel Tank Strap Bolts
                23 N.m (250 in. lbs)
Fuel Rail Bolts
                23 N.m (250 in. lbs)
Ignition Manifold Mounting Bolts
                11 N.m (95 in. lbs)
Intake Manifold Bolts
                 11 N.m (95 in. lbs)
Throttle Control Shield
                5.6 N.m (50 in. lbs)

Camshaft Position Sensor Screw
                9 N.m (80 in. lbs)
SOHC Cam Magnet/Target
                3.4 N.m (30 in. lbs)
DOHC Cam Magnet/Target
                3 N.m (30 in. lbs)
Crankshaft Position Sensor Screw
                9 N.m (80 in. lbs)
Coolent Temp. Sensor
                18.6 N.m (165 in. lbs)
Ignition Coil to Cyl. Head
                22 N.m (200 in. lbs)
Ignition Coil Bracket Nuts
                22 N.m (200 in. lbs)
Knock Sensor
                10 N.m (90 in. lbs)
MAP/IAT Sensor Plastic Manifold
                2 N.m (20 in. lbs)
MAP/IAT Sensor Aluminum Manifold
                3 N.m (30 in. lbs)
Spark Plugs
                28 N.m (20 ft
Fuel System
-----------

Air Cleaner Wingnut
                1.5 N.m (15 in. lbs)
Air CLeaner Mount. Stud-to-Throttle Body
                10 N.m (90 in. lbs)
Crankshaft Position Sensor Mounting Bolts
                8 N.m (70 in. lbs)
Engine Coolant Temp Sensor
                18 N.m (165 in. lbs)
IAC Motor-to-Throttle Body Bolts
                7 N.m (60 in. lbs)
MAP/IAT Sensor
                2 N.m (20 in. lbs)
MAP/IAT Sensor
                3 N.m (30 in. lbs)
Oxygen Sensor
                28 N.m (20 ft. lbs)
Powertrain Control Module (PCM) Mounting Screws
                4 N.m (35 in. lbs)
Throttle Cable Cover
                4.5 N.m (40 in. lbs)
Throttle Body Mounting Bolts
                23 N.m (200 in. lbs)
Throttle Postion Sensor Mounting Screws
                2 N.m (20 in. lbs)
Vehicle Speed Sensor Mounting Bolts
                2.2 N.m (20 in. lbs)

Steering Column Fasteners
-------------------------

Steering Wheel Retaining nut
                61 N.m (45 ft. lbs)
Steering Column Upper and Lower Mounting Bracket Attaching Nuts
                17 N.m (150 in. lbs)

Clutch
------
Modular Clutch
        Drive Plate to Clutch Bolts
                75 N.m (55 ft. lbs)
        Drive Plate to Crankshaft Bolts
                95 N.m (70 ft. lbs)
        Clutch Pedal Pivot Shaft Nut
                41 N.m (30 ft. lbs)

Conventional Clutch
        Clutch Cover Bolts
                28 N.m (250 in. lbs)
        Flywheel to Crankshaft Bolts
                95 N.m (70 ft. lbs)
        Clutch Pedal Pivot Shaft Nut
                41 N.m (30 ft. lbs)

Charging System
---------------
Battery Terminal Nut
                9 N.m (75 in. lbs)
Battery Hold down Clamp Bolt
                9 N.m (75 in. lbs)
Generator Mounting Bolt
                54 N.m (40 ft. lbs)
Generator Pivot Bolt
                54 N.m (40 ft. lbs)

Turn Signals
------------
Multi Function switch to Column retaining screws
                2 N.m (17 in. lbs)
Steering Column Cover Retaining Screws
                2 N.m (17 in. lbs)

Wheels
------
Wheel Mounting Stud Size
                M12 x 1.5 mm
Wheel Mouning Nut Hex Size
                19mm
Wheel Mouning Nut Torque
                115-155 N.m (85 to 115 ft. lbs)

Suspension
----------

Strut Assembly
        To Body Attaching Nuts
                34 N.m (300 in. lbs)
        Clevis Bracket to Knuckle Nut/Bolt
                95 N.m (70 ft. lbs)
        Strut Assembly Shaft
                75 N.m (55 ft. lbs)

Brake Support Plate
        To Knuckle Bolts
                68 N.m (50 ft. lbs)
Stabilizer Bar
        Bushing Retainer To Frame Bolt
                34 N.m (300 in. lbs)
        To Strut Attaching Link Nut
                34 N.m (300 in. lbs)

Tension Strut
        Shaft Nut
                95 N.m (70 ft. lbs)
        Bracket to Body Attaching Bolts
                95 N.m (70 ft. lbs)

Lateral Link
        Attaching Nut
                95 N.m (70 ft. lbs)

Disc Brake Caliper
        To Atapter Mounting Bolt
                22 N.m (16 ft. lbs)
        Brake Hose to Caliper Mounting Bolt
                45 N.m (35 ft. lbs)
        Adapter to Knuckle Mounting Bolt
                68 N.m (50 ft. lbs)

Brake Hose
        Bracket Mounting Bolt
                23 N.m (17 ft. lbs)

Hub and Bearing
        To Knuckle Retaining Nut
                216 N.m (160 ft. lbs)
        Wheel Stud Lug Nuts
                109-150 N.m (80-110 ft. lbs)

EGR
---
EGR Valve to Cyl. Head
                22 N.m (200 in. lbs)
EGR Tube to EGR Valve
                11 N.m (95 in. lbs)
EGR Tube to Intake Manifold
                11 N.m (95 in. lbs)

Differential and Driveline
--------------------------

Caliper to Knuckle Bolt
                31 N.m (23 ft. lbs)
Driveshaft Nut
                183 N.m (135 ft. lbs)
Front Wheel Lug Nuts
                135 N.m (100 ft. lbs)
Knuckle To Ball Joint Bolts
                95 N.m (70 ft. lbs)
Tie Rod End To Knuckle
                61 N.m (45 ft. lbs)

Frame and Bumpers
-----------------
Front Bumper Reinforcement Nut
                156 N.m (115 ft. lbs)
Rear Bumper Reinforcement Nut
                156 N.m (115 ft. lbs)
Front Crossmember To Body Mounting Bolts
                163 N.m (120 ft. lbs)

Brakes
------
Wheel Speed Sensor to Tone Wheel Clearance
        Front
                Minimum Clearance  0.17mm
                Maxamum Clearance  1.80mm
        Rear
                Minimum Clearance  0.37mm
                Maxamum Clearance  1.50mm

Brake Tubes
        Tube Nut To Fittings and Components Except HCU
                17 N.m (145 in. lbs)
        From Master Cylinder to HCU at HCU Ports
                21 N.m (185 in. lbs)

Brake Hose
        To Caliper Banjo Bolt
                48 N.m (35 ft. lbs)
        Intermediate Bracket
                12 N.m (105 in. lbs)

Master Cylinder
        To Vacuum Booster Mounting Nut
                28 N.m (250 in. lbs)

Brake Booster
        To Dash Panel Mounting Nuts
                28 N.m (250 in. lbs)
Rear Wheel Cylinder
        To Support Plate Mounting Bolts
                13 N.m (115 in. lbs)
        Bleeder Screw
                10 N.m (80 in. lbs)

Brake Support Plate
        To Axle Mounting Bolts
                75 N.m (55 ft. lbs)

Rear Disc Brake Adapter
        To Axle Mount Bolts
                75 N.m (55 ft. lbs)

Disc Brake Caliper
        Guide Pin Bolts
                22 N.m (192 in. lbs)
        Bleeder Screw
                15 N.m (125 in. lbs)

ABS Hydraulic Control Unit
        To Mounting Bracket Bolts
                28 N.m (250 in. lbs)
        Bracket To Frame Rail Mounting Bolt (top)
                18 N.m (160 in. lbs)
        Bracket to Frame Rail Mounting Bolt (side)
                22 N.m (200 in. lbs)

Parking Brake
        Lever Mounting Nuts
                28 N.m (250 in. lbs)

Rear Hub and Bearing
        To Knuckle Retaining Nit
                217 N.m (160 ft. lbs)
31TH Automatic Transaxle
------------------------
Torque Converter
        Diameter
                241mm (9.48 inches)
        Oil Capacity
                8.6L (18.25 Pints)
        Oil Type
                Mopar ATF Plus 3 Type 7176
        Cooling Method
                Water Heat Exchanger and/or air to oil heat exchanger
        Lubrication
                Pump (internal-external gear type)

Gear Ratios
  Transmission Portion
        First Gear      2.69
        Second Gear     1.55
        Third Gear      1.00
        Reverse         2.10

 Pump Clearances
        Outer Gear to Pocket
                0.045-0.141mm (0.0018-0.0056 in.)
        Outer Gear Side Clearance
                0.020-0.046mm (0.0008-0.0018 in.)
        Inner Gear side Clearance
                0.020-0.046mm (0.0008-0.0018 in.)

 Tapered Roller Bearing Settings
        Differential Assembly
                6 to 12 in. lbs Drag Torque
        Output Hub
                0 to 3 in. lbs Drag Torque
        Transfer Shaft
                0.002 to 0.010 in. End Play
        Overall Drag At Output Hub Torque
                3 to 16 in. lbs. Drag Torque

MISC
----
Washer Reservoir
                2.2-3.3 N.m (20 to 29 in. lbs)







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Last edited by Matt Wiggins on Wed Mar 08, 2006 12:03 pm, edited 1 time in total.

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PostPosted: Tue Mar 07, 2006 7:56 pm 
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Location: Andover, Minnesota
Here's some others:
Code:
Exhaust Manifold Bolts: 17 Ft/lb

Main Bearing Cap: 8mm bolts- 25 ft/lb, 11mm bolts- 60 ft/lb
If these are incorrect just let me know.

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'96 Strawberry Coupe 2.4L w/ 3.94 .81 5th


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PostPosted: Tue Mar 07, 2006 8:54 pm 
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Thank You! Just cicked print.


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PostPosted: Tue Mar 07, 2006 9:04 pm 
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Code:
Connecting Rod Cap Bolts: 21ft/lb + 90 degrees on a breaker bar.

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PostPosted: Wed Mar 08, 2006 11:05 am 
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Location: Andover, Minnesota
Code:
Specs for brake rotor turning: Minimum thickness- .724 (in thousandths of an inch)

Firing order: 1-3-4-2

Fuel system pressure: 49psi

Again if these are not the correct specs feel free to correct them.

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'96 Strawberry Coupe 2.4L w/ 3.94 .81 5th


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PostPosted: Wed Mar 08, 2006 12:04 pm 
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Updated Wed March 8th. I will include other peoples updates once I get all of the Manual stuff in.

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PostPosted: Sun Mar 12, 2006 4:14 pm 
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98Neon DOHC wrote:
Code:
Specs for brake rotor turning: Minimum thickness- .724 (in thousandths of an inch)

Firing order: 1-3-4-2

Fuel system pressure: 49psi

Again if these are not the correct specs feel free to correct them.


That is the correct firing order, however, the neon has a wasted spark setup so #1 and #4 always fire at the same time as do #2 and #3. Maybe some info to include..

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PostPosted: Mon Mar 27, 2006 1:45 pm 
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Joined: Mon Dec 13, 2004 10:25 pm
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Location: Columbus, Ohio
So a 96 is supposed to have a 12.5 gallon fuel tank? My owner's manual says 11.2 and I can hardly believe that's right. I usually fill up when I have 1/8 of a tank left, and when I fill up I only put in 9.5 gallons or so...that doesn't make sense that it holds 12.5 gallons (I think I would be putting closer to 11 in when almost empty). Where did you get this info?

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PostPosted: Mon Mar 27, 2006 1:56 pm 
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a 96 could have 11.2 or 12.5 depending on when the switch was made. I think only early 96's had it, but its been a while and I could be wrong.

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PostPosted: Mon Mar 27, 2006 2:52 pm 
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Just check for a plastic or metal tank.

Ted

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 Post subject: tank
PostPosted: Sat Apr 15, 2006 12:16 am 
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Most 1996 neons were built with the steel gas tank like the '95s had. They changed over to the plastic tank partway through the '96 model year, but changed back to the steel tank not long after that due to some sort of production snag. The plastic tank came back for good when they started building '97 model year neons.

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PostPosted: Tue Apr 18, 2006 12:58 am 
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good info and lots of it, but i always get confused with the in lbs and ft lbs, maybe add a link to a conversion calculator or just some basics with like 5 in lbs converted to ft lbs, kinda like 5 in lbs = 1 ft lbs i dont know how it goes and maybe others dont either


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PostPosted: Wed Apr 19, 2006 1:41 am 
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Hey Matt do you know the torque specs. for the head and rocker arm shafts on the 2.0 sohc?


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PostPosted: Wed Apr 19, 2006 1:47 am 
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Rocker Arm Shaft Bolts: 250 in. lbs.

Head:
http://www.neons.org/neontsb/TSB/09/090598.htm

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PostPosted: Wed Apr 19, 2006 12:44 pm 
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Thanks man thats exactly what I needed!


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PostPosted: Wed Apr 19, 2006 2:42 pm 
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LilRed wrote:
good info and lots of it, but i always get confused with the in lbs and ft lbs, maybe add a link to a conversion calculator or just some basics with like 5 in lbs converted to ft lbs, kinda like 5 in lbs = 1 ft lbs i dont know how it goes and maybe others dont either



Or maybe just google a calculator up? ;)

Strangely though...

There's 12 inches in a foot.
There's 12 inch-lbs in a ft-lb too.

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'05 MCS | '99 ACR | Ducati M750

So, when your Mexican motor explodes, will candy come out? -Reed
Less is more, and the big things are often the little things that someone would overlook. -Roysneon
Sometimes I feel like I'm reading what 800 monkeys wrote before they stumbled onto Shakespeare. -Me
Awesome, you figured out the keyboard. Now you can arrange letters to make words. -Ben
My sauce is awesome because I innovate. Your sauce is weak because you replicate. -Me


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PostPosted: Thu Apr 27, 2006 3:37 am 
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so 120 in lbs = 10 ft lbs?


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PostPosted: Thu Apr 27, 2006 6:53 am 
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http://www.onlineconversion.com/torque.htm

There ya go, and yes.

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PostPosted: Wed Aug 16, 2006 12:52 am 
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what about dohc cam caps?

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2.4 swap,55mm TB, SRT wheels, Pacesetter header>2.5 cat>2.5glasspack>straight thru muffler, Ksport coilovers ,MSD DIS2,clear 3rd brake light, Depo Projectors Is300 style tails Custom gauge cluster, airfilter, 3.0l CAI 75 wet shot ...You must be refuring to the Srt Design group sxt... Dolled up like an srt minus the side skirts, and the testicals...


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PostPosted: Wed Aug 16, 2006 12:57 am 
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Neon Enthusiast

Joined: Sun Sep 05, 2004 2:33 pm
Posts: 2025
Location: ReedsBurg WI 53959
great post!

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APN wrote:
Temporary fix: Hammered the dent out with a bottle of "code red" and spray painted it white.


99 R/T hahn stg 2, SRT 4 fmic, Maddog sts, MPX pulley, 2.5" exhaust w/ magnaflow muffler, greddy knock off bov, phantom grip lsd, diff pin, and diff saver tabs, ClutchMasters Stage 3 Clutch, homemade mbc, 55mm throttle body, egr blocked off, no ac and no ps, srt internals 2.4 now :twisted:
best E/T with 2.4:

best E/T: 13.701@105.44 with 2.0

awaiting a tune for 15-18psi :twisted:


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PostPosted: Wed Aug 16, 2006 1:08 am 
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Retired Moderator

Joined: Sat Mar 15, 2003 10:53 pm
Posts: 4680
Location: Saskatoon, SK, CA
Cam Caps

M6 Bolts (smaller): 12 N*m
M8 Bolts (larger): 24 N*m

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Scott
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2003 Nissan Sentra SE-R Spec V
1997 Dodge Neon Sport Coupe - DOHC 3.94
FS: 2.0L Sealed Power main bearings


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