Repair Procedure

This bulletin outlines the proper procedures for preparing head/block surfaces for MLS gasket installation.

1. Following service manual procedures, remove the head.

2. Remove as much of the loose composite gasket material with a plastic or wooden scraper.

NOTE:
PRIOR TO ADDITIONAL CLEANING, INSPECT THE COOLING PASSAGES OF THE HEAD. REPLACEMENT MAY BE NECESSARY IF EXCESSIVE PITTING OR EROSION HAS TAKEN PLACE THAT WILL COMPROMISE THE SEALING SURFACES AROUND THE COOLING PASSAGES.

3. Cover coolant and oil passages to the best of your ability and apply solvent or a commercially available gasket cleaner to the head/block surfaces. Allow the solvent to soften the remaining composite gasket material.

4. Using a plastic or wooden scraper, scrape the composite gasket residue from the surfaces. If necessary, apply additional solvent or gasket remover to ease removal.

5. If additional cleaning is needed, use a drill motor and 3M Roloc bristle disc p/n 07528 (white) to carefully remove the remaining gasket material from the head and block surfaces.

NOTE:
IF DIFFICULT TO REMOVE RESIDUE IS LEFT, THE YELLOW ROLOC BRISTLE DISK 3M P/N 07525 CAN BE USED. USE EXTREME CARE WHEN POWER CLEANING ALUMINUM SURFACES TO PREVENT METAL TRANSFER.

6. Inspect the sealing surfaces for any remaining composite gasket residue. Carefully remove any remaining material.

7. The head and block must be checked for flatness. Follow service manual procedures/specifications where applicable.

8. Spray both sides of the MLS gasket with a coat of MOPAR spray gasket sealant p/n 04318035.

9. Re-assemble the engine as outlined in the appropriate service manual. Pay particular attention to head bolt torque and torqueing procedures. All head bolts should be oiled prior to assembly.

NOTE:
THE 2.0L DOHC TORQUE AND TORQUING PROCEDURE HAS CHANGED WITH THE INSTALLATION OF A MLS GASKET. USE THE FOLLOWING PROCEDURES FOR THE 2.0L DOHC ONLY.

2.OL DOHC TORQUE PROCEDURE WITH MLS GASKET INSTALLATION

NOTE:
THE 4 SHORT BOLTS ARE PLACED IN THE CORNERS.

A. Torque all center bolts to 34 Nm (25 Ft Lbs), Torque the 4 corner bolts to 27 Nm (20 Ft Lbs) see Fig 1 for torque sequence.

B. Torque all center bolts to 68 Nm (50 Ft Lbs), Torque the 4 corner bolts to 47 Nm (35 Ft Lbs) see Fig 1 for torque sequence.

C. Re-torque all center bolts to 68 Nm (50 Ft Lbs), Re-torque the 4 corner bolts to 47 Nm (35 Ft Lbs) see Fig 1 for torque sequence.





D. Tighten all bolts in the specified sequence (Fig 1) an additional 90° (1/4 turn).

10. Make sure the cam sensor seal is replaced on all engine applications.

NOTE:
A NEW CAM SENSOR SEAL MUST BE INSTALLED DURING THE HEAD GASKET REPLACEMENT PROCEDURE. OIL SEEPAGE FROM THIS SEAL CAN BE MISINTERPRETED AS A HEAD GASKET LEAK.

11. Replace the engine oil and filter after performing these procedures.