Dodge Viper SRT-10 (ZB). Manual — part 178
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 50° to 60°
for proper seating of rings (Fig. 81).
(4) A controlled hone motor speed between 200 and
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 50° to 60°
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
CLEANING
CAUTION: Remove all gasket material from cylinder
block using a plastic gasket scraper and Mopar
T
Brake Parts Cleaner or the equivalent, this will pre-
vent damage to the cylinder block.
(1) When cleaning the cylinder block, remove the
oil gallery plugs at the front and rear of the block.
(2) Spray compressed air into all oil gallery pas-
sages to ensure they are clear of blockage.
(3) Use a wooden or plastic scraper and Mopar
t
Brake Parts Cleaner or the equivalent to remove the
old gasket.
(4) Clean the oil passages in the crankshaft with a
brush.
INSPECTION
The cylinder walls should be checked for out-of-
round and taper with Special Tool C-119 (1) (Fig. 82).
If the cylinder walls are badly scuffed or scored, the
cylinder bore can be machined oversize. Oversize pis-
ton and rings are available.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 82). Top measurement should be
12 mm (0.50 in.) down and bottom measurement
should be 12 mm (0.50 in.) up from bottom of bore.
(Refer to 9 - ENGINE - SPECIFICATIONS) for cylin-
der bore and piston specifications.
Fig. 82 Measuring Cylinder Bore Size
1 - BORE GAUGE
2 - CYLINDER BORE
3 - 2-5/16 in.
9 - 54
ENGINE
ZB
ENGINE BLOCK (Continued)
HYDRAULIC TAPPETS
DESCRIPTION
The roller type design hydraulic tappets (3) are
positioned in the cylinder block. Roller tappet align-
ment is maintained by machined flats on tappet body
being fitted in pairs into ten aligning yokes (2) (Fig.
84).
REMOVAL
(1) Remove cylinder head(s) (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
NOTE: If tappets (3) are to be reused, identify tap-
pet location to ensure installation in original loca-
tion.
(2) Remove tappet aligning yoke bolt (1) (Fig. 84).
(3) Remove tappets (3) from bores.
CAUTION: Do not disassemble tappets.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets in their original positions with
oil holes (1) facing up (Fig. 85).
CAUTION: The “handle” on the tappet aligning yoke
must be installed in the outboard position; i.e.
toward the cylinders.
Fig. 83 Hydraulic Tappets
1 - BOLT
2 - ALIGNING YOKE
3 - HYDRAULIC TAPPET
Fig. 84 Hydraulic Tappets
1 - BOLT
2 - ALIGNING YOKE
3 - HYDRAULIC TAPPET
Fig. 85 Tappet Oil Holes
1 - OIL HOLES UP FOR INSTALLATION
ZB
ENGINE
9 - 55
(3) With roller tappets in proper position, install
aligning yoke assemblies. Apply Mopar
t Lock & Seal
Adhesive (Medium Strength Threadlocker) to the
screws and tighten to 11 N·m (95 in. lbs.) (Fig. 84).
(4) Install cylinder heads (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(5) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
CAMSHAFT
REMOVAL
(1) Remove engine from vehicle (Refer to 9 -
ENGINE - REMOVAL).
(2) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(3) Remove cylinder head covers (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(4) Remove timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING CHAIN COVER -
REMOVAL).
(5) Remove rocker arm assemblies.
(6) Remove push rods. Identify each push rod to be
replaced in its original location.
(7) Remove cylinder heads (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(8) Remove
hydraulic
tappets
(Refer
to
9
-
ENGINE/ENGINE BLOCK/HYDRAULIC TAPPETS -
REMOVAL).
(9) Remove timing chain and camshaft sprocket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
CHAIN AND SPROCKETS - REMOVAL).
(10) Remove camshaft thrust plate (Fig. 86).
(11) Remove camshaft being careful not to damage
camshaft bearing surfaces with the cam lobes (Fig.
86).
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals.
(2) Install camshaft being careful not to damage
camshaft bearing surfaces with the cam lobes (Fig.
86).
(3) Install camshaft thrust plate with two screws
as shown in (Fig. 86). Tighten to 24 N·m (210 in.
lbs.).
(4) Install timing chain and camshaft sprocket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
CHAIN AND SPROCKETS - INSTALLATION).
(5) Measure camshaft end play. End Play should
measure 0.0127–0.381 mm (0.005–0.015 in.) 0.381
mm (0.015 in. Max.). If not within limits, install a
new thrust plate.
(6) When camshaft is replaced, all of the tap-
pets must be replaced. Each hydraulic tappet must
be installed with oil hole facing up (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC TAPPETS -
INSTALLATION).
(7) Install
timing
chain
cover
(Refer
to
9
-
ENGINE/VALVE TIMING/TIMING CHAIN COVER -
INSTALLATION).
(8) Install cylinder heads (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(9) Install push rods in their original location.
(10) Install rocker arms (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION).
(11) Install intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLA-
TION).
(12) Install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION).
(13) Install engine in vehicle (Refer to 9 - ENGINE
- INSTALLATION).
Fig. 86 Camshaft and Thrust Plate
1 - CAMSHAFT
2 - THRUST PLATE
3 - BOLT(S)
9 - 56
ENGINE
ZB
HYDRAULIC TAPPETS (Continued)
PISTON & CONNECTING ROD
DESCRIPTION
The pistons are made of cast aluminum. Three pis-
ton rings are used; two compression and one three-
piece oil control ring. The piston pin (press-fit into
the rods) joins the piston to a forged steel, fractured
cap, designed connecting rod. The piston and con-
necting rod is serviced as an assembly.
STANDARD PROCEDURE
PISTON FITTING
All pistons are machined to the same weight in
grams, to maintain piston balance.
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin axis at size location shown in (Fig. 87).
Cylinder bores should be measured halfway down the
cylinder bore and transverse to the engine crankshaft
center line shown in (Fig. 88). (Refer to 9 - ENGINE
- SPECIFICATIONS) for cylinder bore and piston
specifications.
NOTE: Pistons and cylinder bores should be mea-
sured at normal room temperature, 70°F (21°C).
MEASURING CONNECTING ROD SIDE
CLEARANCE
(1) Using a feeler gauge, check connecting rod side
clearance (Fig. 89). (Refer to 9 - ENGINE - SPECIFI-
CATIONS) for connecting rod side clearance specifi-
cations.
Fig. 87 Piston Size Location
Fig. 88 Measuring Cylinder Bore Size
1 - BORE GAUGE
2 - CYLINDER BORE
3 - 2-5/16 in.
Fig. 89 Measuring Connecting Rod Side Clearance
ZB
ENGINE
9 - 57
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