Join Date: Aug 2011
Location: Hudson, Colorado
2002 2.7, P0016, overheat's and rev limiter.
Hello, My Name is Scott and i'm a new bee here. My story is a long one, But it's what happened and i had no control over it.
It all started 4 year's ago when my x wife and her new husband helped my son and his wife buy this 2002 2.7 intrepid. On the way to there house it overheated and sence there was no warranty, My son and his father in law took the motor out and STARTED rebuilding it,
The short block was built, timing chain's and guides bought and then the problem with the head's. The car has less than 90.000 mikes on it and the father in law wanted to replace the valve guides. As he was driving out the guides he missed the guide and hit the head and put a dent in it where the head gasket seals. So in less word's, 2 set's of head's were bought from salvage yard's and just this last year the father in law was feeling ill and diagnosed with lung cancer.
So the job was on hold Until my Youngest daughter bought the car from her mom because my son no longer wanted the car and wanted it fixed and asked me for help sense her father in law was too sick to finish it. I sent the head's out to a machine shop to get them serviced and valve stem height all checked. Then for the short block, Well it was sitting on the porch uncovered and now the cyc's are rusty. So off to my shop i go, tear down the block and get it honed and order new ring's.
Got the short block built and the head's installed and started on the timing chain's and sprocket's. Having never seen this engine or the car before i started sorting out the many cam's and extra part's. The timing chain set was opened and low and behold, the left cam sprocket was a sbec sprocket and the one i thought went with the engine was a ngc.
I went ahead and installed the sbec sprocket, only to find out i needed a ngc sprocket. I ordered the new ngc sprocket, tore out the front cover and installed the new sprocket. I checked 3 times to ensure the timing chain was correctly installed and bar'd the engine over until the mark's came up again and there correctly timed.I even installed the stop block from fix27engine and now the engine is ready to install in the car.
Loaded the car on the car trailer and hauled it to my shop. Went to install the flex plate and i was missing i bolt. So off to the dodge dealer to order a new bolt, Back the next day to find they ordered a flex plate to converter bolt instead and had the flex plate to crank bolt in stock. That cost me 30 miles and time. Got the flex plate installed and the engine dropped in only to NOT find the trans to engine mounting bolt's, (remember i didn't take this thing apart)
Now off to the salvage yard and found the bolt's and the mission continues. I left the exhaust manifold's off the engine and went to install the right one when i realized i put a non egr valve manifold on and there was an egr valve in a box, of off it came and a egr valve manifold was put on. Then i went to install the egr valve and realized the egr valve wasn't all there. There was no place for the egr gas to go into the engine and no connector to plug into the egr.
Good thing my neighbor has a 2000 intrepid to look at. I then realized the egr valve must of been on one of the used head's he bought and for the 3rd tine, Off came the right exhaust manifold and back on goes the one i first put on. I got every thing back together, with the help of the other car to look at and some times putting a piece on 5 times. Now i'm down to the radiator and electric fan's witch can't b found,
So off to the salvage yard. Got a rad and fan's, pressure washed out the rad, Got them installed with a new battery and fill the cooling system and bleed out the air. With it full of oil and cranked for 3 min, and it started. Noisy at first until the lifters filled up and the cel is on with code P0016. I know it's timed right and the correct left cam sprocket is installed. Also it was hard to bleed the air out and i'm not sure it's all out, It had a defective rad cap on it and i had one, But it's not a 16 pounder, so it may be the rad cap's that's on it dealing me fit's with blowing out the coolant.
The other thing that's happening is it act's like it has a rpm limiter on it. It will run to 2200 to 2500 rpm's and limit's there. There is a problem between the crank and cam sensor and i have a new cam sensor for it and i really don't think that will fix it and i don't want to try it and waste the money. I also have a new rad cap to install and see if it still want's to blow out the coolant. Is there any way i got the cam's in the wrong head? I know the difference between the exhaust and intake, but left to right?
I have no idea which cam's came from witch head.
Also i had no idea what this round sensor was wired to the engine harness with a stud through it. Come to find out it is the knock sensor that should of been bolted to the block valley bolt hole before the right head was installed. Opp's, well i didn't know and there no pictures of it in the service manual.
. I found out where it went on one of the many trip's to the salvage yard. I saw a 2.7 with the head's off and there was the sensor. So sence the head's were already on and there is no way to put it where it need's to go. So i'm gonna try bolting it to the head for now.
Sorry to bore every one out, But i felt it better to explain the hole ordeal and what i'm going through to finish the job and get the car going for my daughter.
BTW The father in law passed away 2 week's ago from cancer so he's no longer around to ask questions about the car. But with ever one's help. i can finish his job he started and he will be smiling down from heaven and see her driving the car. Tks and god bless. C-ya Scott
Last edited by slingslingbinks; 08-06-2011 at 11:28 PM.
Reason: Spacing as needed to read the thread better