DIY Network

Mopar Turbo Upgrade: Air-Box Removal From "Tricked Out" episode DTRK-110

	The project car: a 2003 Dodge Neon SRT-4, Mopar's entry into the import-dominated world of sport compacts. "SRT" is an acronym for "street-racing technology." The 2.4-liter turbocharged engine produces 215 horsepower and 245 foot-pounds of torque in standard dress. Right off the lot, the Neon is one of the fastest cars Dodge has ever made.
	Previous mods under the hood: functional hood-scoop and upgraded coil and plug-wire set for hotter spark.
	Other mods include an after-market 3" exhaust and coil-over suspension.

In this episode of Tricked Out, host Andrew Totolos installs a turbo performance upgrade -- including new high-flow fuel injectors -- on a 2003 Dodge Neon. The kit also includes a re-mapped computer that will work together with the other mods to make this 2.4-liter turbo scream.

In this first segment, Andrew introduces the project car -- a 2003 SRT-4 Neon. He also introduces Gary Howell of Howell Automotive® who will be helping with the installation of the Mopar Stage-1 kit. To begin the project, Andrew removes the factory-installed air box.

Materials used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

Mopar Stage-1 kit, including:

• Set of four 527-cc/minute fuel injectors
  
• Mopar performance power-trained control module
  

Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

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Guest expert and performance specialist Gary Howell.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

Safety Alert: Always have a fire-extinguisher handy when working on open automotive-fuel systems.

DIY Difficulty Rating for This Project: We gave this a difficulty rating of 3 on a 5-point intermediate-level scale. There's no cutting or drilling involved, but you do have to open up the fuel system to install the modifications.

Figure A

Removing the Air-Box

The first phase of the project is the computer-module upgrade. The SRT-4 control unit is located underneath the factory air box. To swap out the computer, the air box must first be removed.

• Before you begin, disconnect the negative battery cable (figure A) to keep from accidental starting and to prevent damage to your electrical system.
  

• Remove the clean-air pipe from the air box by loosening the hose clamp at the junction (figure B). Pull the pipe free from the air box and out of the way.

• The crankcase ventilation hose brings air from the crankcase to the air box for emission control. Disconnect it (figure C) and tuck it aside.

  Figure B

  Figure C

  
  

• Disconnect the ambient air temperature sensor by sliding up the red safety catch and pulling the plug (figure D).

• The turbocharger's solenoid measures intake air pressure in the air box. It's held in place with two screws. Loosen and remove the screws (figure E) The unit can be left connected and tucked out of the way for this particular project.

  Figure D

  Figure E

  
  

• Release the two wiring harness clips from the side and the front of the air box with a door panel removal tool (figures F and G).

  Figure H

  Figure I

  
  

• Pull off the make-up air hose from the air box outlet pipe.

• There's a bolt to remove at the front left corner of the box (figure H) and one buried between the air box and the fuse panel on the fender side.

• With everything disconnected, the box is still a little tough to maneuver out (figure I). Tuck the crankcase ventilation hose under the turbo solenoid lines, and gently pull the box up out of the inlet duct on the fender side. Use care, and the air box will pull right out to reveal the power-train control module.

  Figure F

  Figure G

  
  

RESOURCES :

Special Resources for Tricked Out, episode 110

Howell Automotive
Website: www.howellautomotive.com

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526