Inspection; Installation; Engine Block Description; Standard Procedure - Cylinder Bore Honing - Dodge Intrepid Service Manual

LH
ROCKER ARMS (Continued)

INSPECTION

Inspect the cam follower assembly for wear or
damage (Fig. 41). Replace as necessary.
Fig. 41 Rocker Arm
1 – LASH ADJUSTER POCKET
2 – OIL SQUIRT HOLE
3 – ROLLER

INSTALLATION

(1) Lubricate rocker arms with clean engine oil
before installation.
(2) Rotate engine until cam lobe is on its base cir-
cle (heel) of rocker arm being installed.
(3) Using Special Tools 8215 and 8216 Adaptor,
depress valve spring only enough to install rocker
arm (Fig. 40).
(4) Install rocker arm in original position (if
reused) over valve and lash adjuster. Release tension
on valve spring.
NOTE: Inspect rocker arm for proper engagement
into lash adjuster and valve tip.
(5) Repeat procedure for each rocker arm installed.
(6) Install cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER
COVER(S) - INSTALLATION)
ENGINE BLOCK
DESCRIPTION
The cylinder block is made of heat treated alumi-
num with cast-in-place iron liners (Fig. 42). The
block is a closed deck design with the right bank for-
ward. To provide high rigidity and improved NVH,
the block has cast-in contours and ribs, along with
powdered metal 6 bolt main caps (4 vertical, 2 hori-
zontal), with a die cast aluminum structural beam
windage tray mounted to the main caps.
The block design allows coolant flow between the
cylinder bores and an internal coolant by-pass to the
thermostat.
HEAD/CYLINDER
STANDARD PROCEDURE - CYLINDER BORE
HONING
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20–60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Use a light
honing oil. Do not use engine or transmission oil,
mineral spirits or kerosene. Inspect cylinder walls
after each 20 strokes.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marks intersect at 40-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 43).
(4) A controlled hone motor speed between
200–300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40–60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
HEAD
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.

CLEANING

Clean cylinder block thoroughly using a suitable
cleaning solvent.
INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, (Refer to 9
- ENGINE - STANDARD PROCEDURE - ENGINE
CORE AND OIL GALLERY PLUGS).
(3) Examine block and cylinder bores for cracks or
fractures.
ENGINE 2.7L 9 - 39