3.5L build-up

[TCPMeta]

I have been building a 3.5L high Output for my 2000 dodge intrepid. I know it's not a LX but we both LH and LX are related and I thought I would share.

On a different thread I showed some of the engine off. Well I finally got the whole thing finished and all whats left is to wait for new torque convert to flexplate bolts to come in and and a bunch of ATF+4 transmission fluid then I can drop the beast in.

I still don't know if the JBA headers will work. They look like they will fit on the outside of the frame but on the right side it might hit the differential unit since the LH is FWD. I won't know until the engine goes in. If they don't fit I will put them up for sale here for the same price I paid for them. $418.51. They're brand new and stainless steel finished.

The ASP pulley was some what of a pain to install. I cheated by tossing the pulley into the oven at 300*F for 45 minutes. I then lubed up the crank shaft with grease. I also got a piece of 2x4 and a rubber mallet for part of the install. When the 45minutes came up I quickly grab the pulley then tossed it on the crank shaft until it wouldn't go further then used the 2x4 and mallet to hit the pulley in enough so the bolt could catch the threads. I waited until the pulley cooled off a bit then tighten the bolt and it moved the pulley into place. I did a test fit with the A/C belt and the tensioner and it lined up perfectly.


Also I found out the Haynes manual is crap. When I went to pull the old 3.2L motor it said in the manual I had to also remove the tranny. Like hell I was going to take apart the axle and crap. I unbolted the flexplate from the torque converter. The manual said there was three bolts. In fact there was FOUR bolts but it was too late . I removed the three out of the four and tried to pull the motor and the torque converter came out with it and bent the shaft on the torque converter.


I tried to find a cheap used one but everyone wanted 200 and up for it. Since they wanted so much I went and pulled out the phone book and all I could find was places that did rebuilds. Well I came across Florida Torque Converter and they didn't do the rebuilds but the sold reman units. I was surprised of the price. After shipping and tax $185.69 with a lifetime warranty.


Since I was doing a 3.2 to 3.5L swap and didn't have the way to change the PCM unless I spent a crap load on a new PCM and wire harness I had to change out the Cam sprocket and use the one from the old 3.2L motor. Again the haynes manual stated to use a wrench to hold the sprocket then take off the bolt. Well it's impossible because the bolt has a 85LBS torque and has locktight giving it 100 + pounds. Also you have to replace the bolt or it will snap under stress. Well theres a tool that is used for removing the cam sprocket. I forgot the part model but here is what it looks like.

You mount it on the back of the motor at the cam's baring.



You have to do this on both sides and the tool kit comes with two cam holders. Also if you have oil in the motor and you remove the bottom bolt oil will leak out. Just loosen it and swing the cover down. When you put it back together just add some ATV sealant on the threads.

The flexplate is a bit different then what a conventional one looks like. It has what looks like timing marks. A matter of fact thats that it is. But you don't have to have the motor in TDC to bolt it on. Theres 8 bolts in all but the bolt pattern only goes one way so the holes only match up one cernten way.




Like I said I thought I would share this so if you ever plan to remove your motor and get confused on a few things or if you try to use the haynes manual you will know better.

[mfkbmagnum]

Can,t wait to see it run. Looks like it will be a screamer.

[Tbird100636]

If you bent the torque converter that much then you probably damaged the front pump and the input shaft of the trans. Better replace at least the front pump and check that input shaft and clutch assy. When pulling out the input cluth assy. watch for a thrust washer or thrust bearing behind it. You may have to remove the transfer shaft for the left axle to remove the front pump.

[DannyC]

Yea not to mentioned the seal is shot!

[ToddStone]

Good luck with it. Keep us up to date.

[TCPMeta]

The tranny is fine. I had my neighbor that use to work on dodges look at it and he said it's fine. The new torque converter went on with out a problem. The only problem i'm facing with the tranny is a leaky pan but I just have to pull it back off and straighten the flange and should be good to go.

I finally got the motor dropped in but I have a few things to do to it before I can start it up.

[MooNDoGGie]

What intake manifold do you have on there? Its off of an older 3.5L?

Lookin' good man! Those are the JBA header? Looks like they are gonna fit just nice.

[TCPMeta]

What makes the 3.5L a high output is the intake system. The old 3.2L was also a H.O. and since my new motor didn't come with a plenum i'm going to use the old one from my old 3.2L. If I tried to use the LX intake system I wouldn't be able to close the hood.

Heres a picture of my plenum. I tried to use a red metal cast paint job on it but I failed and the base chrome primer gives it that classic car feel.

[charginscott]

Gotta love the feelong knowing it is almost ready to fire. When it fires you have to have that camera going dude!!! Can`t wait to hear it... GOOD LUCK


Scott

[TCPMeta]

Don't worry, I will have video and two cameras going. This isn't the only forum i'm showing this off too. I have plans to share it with them as well. On the other two forums I visit i'm the guinea pig for the headers. The rest of the mods are typical stuff that LH modders and some of you LX guys have done.

The car might be ready tomorrow evening depending if I don't run into any problems. The hard part is done. Just in the matter of plumbing and wiring. Tomorrow morning I need to make a run to homedepot and get a cap to cap off the oil cooler. The oil cooler on the 3.5L are prone to sluge/block up. Also is doesn't flow a damn. While i'm at home depot I'm going to grab some studs and JB weld to fix my tranny pan. JB weld studs into the tranny (Threads stripped out) and use nuts to hold the pan on instead of using bolts. The 42LE and 42RLE are aluminum and prone for threads to strip out.

Might as well add this, I have a little website for my car if you want to check it out http://68.209.133.69

[TCPMeta]

Everything is good to go but I can't get the motor to start. Watch the video and i'm open for ideas and heres a list of things I have checked.

Ground
Relays
It's getting gas
as far as I know it's getting spark

I've gotten two CEL codes and it's PCM memory been wiped and missing EGR.

[Jimsmag06]

I would confirm spark, But first, confirm power to the PCM...maybe a security system issue?

[MagNite]

What makes the 3.5L a high output is the intake system. The old 3.2L was also a H.O. and since my new motor didn't come with a plenum i'm going to use the old one from my old 3.2L. If I tried to use the LX intake system I wouldn't be able to close the hood.

Heres a picture of my plenum. I tried to use a red metal cast paint job on it but I failed and the base chrome primer gives it that classic car feel.

The intakes on the LH 3.5 looked so much better than the lop sided looking ones on our LX's. Plus you could get to all the sparkplugs. I'm guessing that the LX version may be more efficient as the gas mileage ratings for the Intrepid R/T and the Magnum SXT are virtually identical despite the extra weight and worse aerodynamics of the Magnum.

[TCPMeta]

The LH plenum kinda sucks because the throttle body is in the back. The LX plenum looks like a transverse motor sitting long ways.

I'm trying to get a friend that works at Dodge to check it out. To test the spark plugs I would have to pull out the coil and take off the boot then sit it onto of the motor to see if it sparks. Kinda creepy to do that since the motor is full of gas.

[TCPMeta]

Well no go on the help, last night I was checking all of my connections and found a cable I forgot to hook up. I have no idea where it goes so after work I'm going to fine out where it goes. Also i'm going to add a ground to the starter, my starter isn't getting enough ground.