I guess this is a '98 R/T rebuild thread now?

Tell your story about your personal project. Put together something no one else has? Show it off here with pictures and details! Project Logs are allowed within reason. Non Neon projects may be deleted at the Moderators whim. HINT: Keep it about Neons.
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BCoN
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I guess this is a '98 R/T rebuild thread now?

Post by BCoN » Fri Feb 03, 2012 5:18 am

Stats prior to destruction:

Stock bottom end '99 2.4L /w balance shaft delete and SRT/PT oil system.
Stock head milled .030"
2.4L IN, 2.0L EX cams + PT/2.7L valvetrain
3.0L CAI, ported TB (57ish mm), neon intake manifold /w mild casting flash cleanup and ported inlet
24 lb/hr Ford Racing Bosch Design III injectors (EV6 body + early connector) @ 49psi + Stock ACR PCM
Stock 2.0L exhaust manifold/piping into a direct-fit Walker QuietFlow muffler.
Deyeme Racing firm mounts + Booger Racing solid bobble strut
No A/C, No P/S


The fuel trims weren't pretty according to Torque Pro, but it ran great.


New build progress starts on page 4.
Last edited by BCoN on Thu Apr 27, 2017 12:47 am, edited 16 times in total.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: I guess it's my turn... '96 ACR Coupe + N/A 2.4L

Post by sparkysneonsport » Fri Feb 03, 2012 10:47 am

theres a mod you can do involving opening the drain ports in the head, it gets the oil back to the pan faster, the restrictor in the block(idk if this applies to the 2.4 or not) windage tray/crank scraper/oil pan baffles are always a good idea(and now possible with the balance shafts removed)

another thing is to take the pickup tube, un roll the edge, take off the plate that restricts the hole to that little 3/4" slot, and open theat hole up. clean off any shavings, put it back, and reroll the edge. if ur good with a welder, id say to tack weld it so it doesnt fall off in the pan
95 neon sport coupe. SOHC, RAI, Shorty Header, ATX, DIY shift kit. paint is shot, so when i catch up to you at the finish line, watch ur bumper!!

98 r/t sedan with a 2006 pt 2.4(stock pcm btw). she ran... then the tranny gave up on me

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Re: I guess it's my turn... '96 ACR Coupe + N/A 2.4L

Post by sparkysneonsport » Fri Feb 03, 2012 10:50 am

also with it already being a NA block, you wont have the oil squirters under the pistons, meaning you wont get the calibrated leak from those. (which is usually removed and blocked off on the racing engines anyways... by DCR anyways)
95 neon sport coupe. SOHC, RAI, Shorty Header, ATX, DIY shift kit. paint is shot, so when i catch up to you at the finish line, watch ur bumper!!

98 r/t sedan with a 2006 pt 2.4(stock pcm btw). she ran... then the tranny gave up on me

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Re: I guess it's my turn... '96 ACR Coupe + N/A 2.4L

Post by BCoN » Thu Feb 16, 2012 2:09 am

Received my PT oil pan, pickup and filter housing today. OEM EGR block-off on the way along with 24lb Bosch Design III EV6-bodied injectors, an MPx MM adapter, a Stratus engine mount bracket, PT lifters and an N/A PT upper alternator bracket. I also pulled the trigger on a new set of Deyeme Racing engine mounts with the transaxle mount insert flipped for a 2.4L and some radiator brackets with black anodized socket cap screws.

Engine goes on the stand tomorrow to be torn down while the Catera (yep) engine is off at the machine shop. I'm also going to try to clean up the casting slag on the pan and open up the pickup tube a bit with a half-baked plan (don't ask; involves a water hose) to keep metal shavings out of the screen. We'll see how that works...Pics to follow.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: I guess it's my turn... '96 ACR Coupe + N/A 2.4L

Post by BCoN » Fri Mar 09, 2012 3:58 am

A couple blurry cell phone pictures...for 188k miles and 13+ years of abuse I don't think the bottom end looks too hateful. Picture is of the #3 rod bearing and journal.

Image

Image

Image

Image
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: I guess it's my turn... '96 ACR Coupe + N/A 2.4L

Post by sparkysneonsport » Fri Mar 09, 2012 10:42 am

still looks near virgin. :good:
95 neon sport coupe. SOHC, RAI, Shorty Header, ATX, DIY shift kit. paint is shot, so when i catch up to you at the finish line, watch ur bumper!!

98 r/t sedan with a 2006 pt 2.4(stock pcm btw). she ran... then the tranny gave up on me

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Re: I guess it's my turn... '96 ACR Coupe + N/A 2.4L

Post by BCoN » Sat Mar 10, 2012 4:37 am

I was surprised to say the least...the camshafts are worn and camshaft journals and caps are thrashed. I have a spare head from my 2.0L, but I doubt it looks any better. I purchased belalegosi's spare steel oil restrictor to help contol oil to the cylinder head. Also bought a Miller rear main seal installer, crankshaft sprocket installer and camshaft sprocket installer.


A few pictures of the restrictor.
belalegosi wrote:The diameter of the piece is 10.06mm. I measured the oil port in the block to be 10mm. I tried fitting it in my block and it was a tight fit. You would have to use some force to press it in. The one I used was of a slightly smaller diameter, I was able to finger press mine in. Which now in retrospect, not a good idea.

The orifice is 0.1095".
The big end is 0.2510".
Both same as the one I used.

pics:
Image

Image

Image

And here is mine installed in the block:
Image
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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'96 ACR Coupe + N/A 2.4L

Post by BCoN » Wed Mar 14, 2012 9:47 pm

Everything is at the machine shop right now...I received my oil restrictor from belalegosi and my package from Deyeme Racing. :grin: Tear down of the old 2.0L revealed that the idler had failed leaving a hole in the side of the timing covers.
Last edited by BCoN on Fri Mar 16, 2012 1:52 am, edited 1 time in total.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: '96 ACR Coupe + N/A 2.4L

Post by belalegosi » Thu Mar 15, 2012 10:47 pm

in :good:
Image

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Re: '96 ACR Coupe + N/A 2.4L

Post by BCoN » Fri Mar 16, 2012 1:49 am

Tuesday morning we got the .020" over 3.0L Catera engine back from the machine shop. As of this moment we only have to run the wiring harness, hook up the upper intake manifold, the radiator, and the accesories. The Cadillac should be out of the garage by Monday night and we will roll the ACR back in and tear the old, busted 2.0L bottom end out. I hate doing major surgery in a crowded garage...and it's a 3 car garage!

Plans are to have the crank journals polished and chamfered, head milled and everything cleaned after being checked of course. I got a bag of goodies from the local dealership today. I wish would've known that the bolts and self-tapping screws listed as needed in the stickies are included with the timing cover. Oh well, I have a bin full of spare hardware for occasions like this. :blush: I swear I will start taking pictures once some REAL progress has happened! :rofl:
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: '96 ACR Coupe + N/A 2.4L

Post by BCoN » Wed Mar 28, 2012 3:44 am

I'm bored so here is a quick summary of almost everything being done...no updates though. The engine is still at the machine shop.

-bores deglazed, crank chamfered & polished
-stock head milled ~0.030" (roughly 9.9:1 compression ratio)
-2.0L cams with PT/2.7L valvetrain
-PT/SRT timing with Gates Racing belt
-2001-'02 PT oil system with big filter and modified OEM pickup tube
-belalegosi oil passage restrictor
-balance shaft delete
-Clevite "H" rod bearings; "P" main bearings assembled with Mopar green anaerobic sealer
-Sealed Power moly piston rings
-24 lb/hr Ford Motorsport fuel injectors (4 port nozzle with old bosch plug; EV6 bodied)
-Deyeme Racing firm engine mounts
-2.7L clutch

Green = purchased
Red = need to buy
Last edited by BCoN on Sat Apr 28, 2012 1:05 am, edited 1 time in total.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR

Post by BCoN » Tue Apr 10, 2012 1:58 am

Not really an update...

The 2.4L should be back from the machine shop sometime within the next few days. I've recieved a bunch of parts and I'm almost ready to get this engine back together and into the ACR. The only things left to order are piston rings, the oil pump (2002 PT) and the timing components. Then, I can begin assembling the engine!


I, again, have 0 pictures so here is a crappy cellphone pic of my twin brother's new Rotas.

Image
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR

Post by BCoN » Fri Apr 20, 2012 2:50 am

It's slowly coming together.

Image
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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2.4L ACR

Post by Buddy » Fri Apr 20, 2012 8:26 am

Looking good! You planning on painting engine components? Just asking cuz the head and block are different colors lol.
Best 1/4 mile
Pre mag head/crane 16: [email protected](no passenger seats/stuff in trunk)
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Re: 2.4L ACR

Post by BCoN » Sat Apr 21, 2012 12:18 am

The head is cleaned and coated with something my machinst uses on all cylinder heads, but I don't know what it is. He made it quite clear that it's NOT spray paint lol. The block is staying OEM, rusty black mostly because I'm lazy and don't have time to toy around with aesthetics. I've cleaned a few things in my parts washer, but I'm not going to paint stuff going into an ugly, rusty chassis that will be DD'd.

I've been wasting my spare time in the garage starting to cleanup the casting flash and imperfections in the intake manifold. I'm also working on opening up the inlet and 90° bend to better match the ported TB.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR

Post by srt4eh » Sat Apr 21, 2012 10:09 am

nice so far
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2004 Dodge Neon SRT-4
2019 Dodge Durango GT
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Re: 2.4L ACR

Post by BCoN » Thu May 03, 2012 3:41 am

Some pics of my rustbucket...nothing special going on here. Excuse the gigantic mess. We are doing a transmission swap on a 2000 Intrepid as well as building this 2.4L.

Image

Image

The ACR decal on the trunk was made back in '99 or '00 from the GenII Viper ACR logo. I'm surprised it's held up all these years but it IS an original design from the company that was producing decals for Chrysler Corp. at the time (Competition Graphics?).
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR

Post by BCoN » Fri May 11, 2012 3:24 pm

another crappy pic...
Image
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR

Post by sparkysneonsport » Tue May 15, 2012 10:26 am

shes puurty
95 neon sport coupe. SOHC, RAI, Shorty Header, ATX, DIY shift kit. paint is shot, so when i catch up to you at the finish line, watch ur bumper!!

98 r/t sedan with a 2006 pt 2.4(stock pcm btw). she ran... then the tranny gave up on me

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Re: 2.4L ACR

Post by BCoN » Wed May 16, 2012 3:01 am

Well, it's on 2 mounts... :blush:

Image

Managed to leave the battery tray, transmission and axles in and the wheels on while pulling the old engine. The only thing really holding me up at this point is that I'm waiting on the Miller tool to swap the pins at the PCM. I can't seem to get the red locking tab to slide and I'm having trouble removing the pin cover plate...I already snapped the clip off of the accessible side. Any tips? I'd love to hear this thing run today.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR

Post by BCoN » Fri May 18, 2012 1:38 am

Installed the 2.0L balancer, alternator, starter, water hard lines, FMM and solid bobble. At this point the only things left to do are the pin swap, install the harness, install the manifolds and install the radiator. I plan on going through the wiring harness before installing it as I was having issues with CYL 1 in the 2.0L losing spark on hard 1-2 and 2-3 shifts.


I'm really hoping the hood fits...I'm not a fan of the tilted hood look.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR

Post by BCoN » Wed May 23, 2012 2:43 am

Fired up on the first attempt! :good:

All that is left is to swap alternator belts and install the bumper and hood so I can take it for a drive.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR

Post by belalegosi » Wed May 23, 2012 12:03 pm

great!
I used a precision screw driver to disassemble the connectors to re-pin it. Takes some time at first but then you get good at it lol
Image

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Re: 2.4L ACR

Post by BCoN » Wed May 23, 2012 3:37 pm

The Miller tool ended up bottoming out on the pin before releasing the tab so instead of breaking more things we took the cover off and used the little precision screwdrivers. My friend spent 3 hours repairing and lengthening wires on the harness yesterday. The crank pos sensor and o2 sensor wiring had all melted together. The knock sensor wiring was melted and rubbed through. I'm sure there was a few other damaged areas too.


Edit: I'm in the process of letting it cool down from it's first thermal cycle. No codes so far. :good:
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR...is dead.

Post by BCoN » Wed Jun 06, 2012 9:18 pm

20 mile fresh rebuild is now knocking, fml.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR...is dead.

Post by srt4eh » Wed Jun 06, 2012 9:52 pm

That sucks :(
2002 Dodge Neon 2.6L SOHC Stroker
2004 Dodge Neon SRT-4
2019 Dodge Durango GT
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Re: 2.4L ACR...is dead.

Post by BCoN » Thu Jun 07, 2012 12:26 am

My friend said it seems to be leaking oil from between the engine and bellhousing. I didn't look to verify. I was too unhappy to care at the time. I'll be draining the oil and taking the pan off in the next week. I'm not sure what route I'm going to take just yet though.


I did get to drive it enough to agree that the 2.4L should've been (at least) an optional engine. Peak HP comes a little quick for my taste, but the VAST improvement in TQ from idle to north of 5K is well worth it. The car was willing to accelerate from 55+mph with little effort in 5th gear compared to the R/T I have been driving.


Also, I forgot to add that over the last week I had swapped back to the 2.4L intake cam for reasons of stupidity :blush:. I sheared the locating pin on the 2.0L intake cam.
Last edited by BCoN on Fri Jun 08, 2012 2:09 am, edited 1 time in total.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR...is dead.

Post by 95neonhybrid » Thu Jun 07, 2012 9:19 am

cam sensor seal or the valve cover gasket, maybe the rear main seal
95 nyg sport coupe, under construction-- 80% full srt swapped.. stolen
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Re: 2.4L ACR...is dead.

Post by BCoN » Fri Jun 08, 2012 2:07 am

All 3 are new. Rear main seal was installed using the Miller tools. :dunno:


$90 to turn the crankshaft...
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR...is dead.

Post by BCoN » Tue Jun 12, 2012 2:20 pm

#4 rod bearing spun and doubled up, taking out the #5 main bearing which is down to the copper. All bearings are worn from debris and the crank is trash. #4 rod journal is so bad it would take 0.040"-0.050" to get it round again. Crappy cell phone pics later tonight...
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR...is dead.

Post by NickKo » Tue Jun 12, 2012 10:25 pm

BCoN wrote:#4 rod bearing spun and doubled up, taking out the #5 main bearing which is down to the copper. All bearings are worn from debris and the crank is trash. #4 rod journal is so bad it would take 0.040"-0.050" to get it round again. Crappy cell phone pics later tonight...
Question: WHY did it spin ??

Sorry to read about this. :sad:


- Nick
-1998 2-dr SOHC MTX= 52mm TB; Maddog STS
-1999 4-dr DOHC ATX= went to car heaven (junkyard)
-2000 Ply.LX with MTX = Maddog STS; CAI; R/T muffler + Header
-2001 Ddg.ES ATX = UDP, Magnum Header; + Syked PCM 'pending'

-1971 Ply.Scamp SL6cyl. ('Horse Traded' away)
-1968 Chry.300 w/440 V8 (sold)
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Re: 2.4L ACR...is dead.

Post by BCoN » Wed Jun 13, 2012 3:51 pm

I don't know the answer to that question, Nick.

My machinist thinks that either A) the bearing was improperly installed, or B) the bearing had a freak defect. I'm 99.9999% sure that every bearing was in the correct position. I never really beat on the engine and I definetely didn't go hauling around any corners hard enough to run the sump dry. I primed the oil pump upon installation and the engine was primed before being started.


Onto the pictures...

All main pictures are the block side. The bearings in the bedplate looked the same.

#1 main bearing.
Image


#2 main.
Image


#3 main.
Image


#4 main.
Image


#5 main
Image


#1 rod
Image


#2 rod
Image


#3 rod.
Image


#4 rod bearing.
Image


Crankshaft: front half.
Image


Crankshaft: rear half.
Image



I forgot to take a picture of the other #4 rod bearing. Both sides are missing their tab.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR...is dead.

Post by ottoretto » Sat Jun 16, 2012 1:55 pm

i think that the problem could be bad torquing( i dont know if i wrote it right), running low oil, or another posible explanation is bad crankshaft maquination... because is really weird what happen in there
B.T.N.Y.S
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Re: 2.4L ACR...is dead.

Post by BCoN » Sat Jun 16, 2012 11:56 pm

Torque wrench was brand new, followed FSM specs and used a breaker bar for the final TQ step. 5.5qts of 5W-30 in the engine.

I'm just going to put a crankshaft kit and a new rod and piston in and call it finished for the time being. I need a car.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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Re: 2.4L ACR...is dead.

Post by ottoretto » Sun Jun 17, 2012 9:24 am

the crankshaft you used was machined? i mean, could be a bad work on the journal, that is a great posibility of what happened to you my friend
B.T.N.Y.S
Dodge Neon 98 DOHC "Frankenstein": Polished Head, C/R 11:1, 25 lbs/hr Fuel Injectors, Custom LTH, 2.5" pipe with driver back passenger exhaust =), Aluminium Front Strut Bar, Stainless Steel Front Sway Bar, 60mm tb, Syked PCM, Apexi SAFC (trying to tune)

Projects Not Finnished: ITB's, Cam Sprockets
Sequential Shifter CAD Finished =)

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BCoN
Neon Enthusiast
Posts: 1623
Joined: Fri Feb 18, 2005 7:52 pm
Location: Kettering, OH

Re: 2.4L ACR...is dead.

Post by BCoN » Sun Jun 17, 2012 11:50 pm

The crank had stock journals which measured out fine. The oil passages were chamfered and the journals were repolished.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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ottoretto
Neon Enthusiast
Posts: 125
Joined: Mon Jan 19, 2009 11:04 am
Location: Venezuela

Re: 2.4L ACR...is dead.

Post by ottoretto » Wed Jun 20, 2012 9:31 pm

if you have a lighter crank pulley or a lighter flywhell can make that
B.T.N.Y.S
Dodge Neon 98 DOHC "Frankenstein": Polished Head, C/R 11:1, 25 lbs/hr Fuel Injectors, Custom LTH, 2.5" pipe with driver back passenger exhaust =), Aluminium Front Strut Bar, Stainless Steel Front Sway Bar, 60mm tb, Syked PCM, Apexi SAFC (trying to tune)

Projects Not Finnished: ITB's, Cam Sprockets
Sequential Shifter CAD Finished =)

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BCoN
Neon Enthusiast
Posts: 1623
Joined: Fri Feb 18, 2005 7:52 pm
Location: Kettering, OH

Re: 2.4L ACR...is dead.

Post by BCoN » Thu Jun 21, 2012 1:47 am

Both are stock 2.0L parts. I'm buying a set of pistons and rods off of neonrt_98. I still have to order the crank, get a few gaskets, pick my oil pump up from the machine shop and start cleaning everything...again.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

johnwinters8
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Posts: 59
Joined: Sun Mar 25, 2007 2:11 am
Location: missouri

Re: 2.4L ACR...is dead.

Post by johnwinters8 » Thu Jun 21, 2012 2:23 am

when you say you primed oil pump, did you remove sparkplugs to do that?

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BCoN
Neon Enthusiast
Posts: 1623
Joined: Fri Feb 18, 2005 7:52 pm
Location: Kettering, OH

Re: 2.4L ACR...is dead.

Post by BCoN » Thu Jun 21, 2012 10:52 pm

Plugs, wires and coil were removed. Oil pump was packed with petroleum jelly.
- Brett
PW7 '96 ACR Coupe 2.4L - RIP
PX8 '99 ACR Coupe - RIP
PX8 '98 R/T Coupe - 2.0L DOHC. Bolt-ons.

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