Removal and Installation
REMOVAL1. Perform fuel system pressure release procedure before attempting any repairs.
2. Disconnect negative battery cable.
3. Remove power steering/air conditioning drive belt.
4. Raise vehicle.
5. Drain cooling system.
6. Remove exhaust pipe from manifold.
7. Remove right front wheel.
8. Remove right side splash shield.
9. Remove generator belt.
10. Remove crankshaft damper.
11. Remove lower torque strut.
12. Lower vehicle and remove upper torque strut.
13. Remove ground strap and power steering hose support clip from engine mount bracket.
14. Remove power steering pump assembly and set aside.
15. Support engine from beneath with a suitable jack.
16. Remove right side engine mount to bracket through bolt.
17. Remove the lower engine mount bracket bolt. Raise engine slightly and remove the upper engine mount bracket bolts.
18. Remove engine mount bracket. This procedure may require additional raising/lowering of engine until bracket will clear engine components.
19. Remove front timing belt cover.
20. Rotate engine until timing marks are aligned.
21. Remove timing belt and tensioner.
22. Remove camshaft sprocket.
23. Remove rear timing belt cover.
24. Disconnect fuel line at fuel rail.
25. Remove coolant recovery container.
26. Remove ground wire to cylinder head.
27. Remove upper radiator hose.
28. Remove intake manifold.
29. Disconnect ignition coil electrical connector. Remove coil pack and spark plug cables from engine.
30. Remove Crankcase Closed Ventilation (CCV) hose from cylinder head cover.
31. Disconnect cam sensor and coolant temperature electrical connectors.
32. Remove heater tube to cylinder head attaching fasteners.
33. Remove heater hose from thermostat housing connector.
34. Remove cylinder head cover.
35. Remove cylinder head bolts.
Fig. 55
36. Remove cylinder head and gasket (Fig. 55).
Fig. 56
NOTE: Inspect camshaft bearing journals for scoring. Cylinder head must be flat within 0.1 mm (0.004 inch) (Fig. 56).
INSTALLATION
EXAMINING CYLINDER HEAD BOLTS
Fig. 57
NOTE: The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolt(s) should be replaced (Fig. 57).
Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt(s) should be replaced.
CLEANING CYLINDER HEAD SEALING SURFACES
Fig. 58
CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper. Sealing surfaces could be cut or ground, resulting in gasket leaks. Use only the cleaning methods shown in (Fig. 58). If required, use a white (120 grit) 3M Roloc bristle disk on aluminum surfaces. A yellow (80 grit) bristle disk can be used on cast iron surfaces with care.
1. Clean the cylinder head and cylinder block sealing surfaces using a wood/plastic scraper. Apply solvent or a commercially available gasket remover to help soften the gasket residue. If additional cleaning is required, use a white (120 grit) 3M Roloc bristle disk and a drill motor to remove gasket residue.
2. Apply Mopar Gasket Sealant (aerosol can) to both sides of the new cylinder head gasket.
3. Position a new cylinder head gasket on the locating dowels.
Fig. 59
4. Position crankshaft sprocket to TDC, then rotate crankshaft until mark is three teeth before TDC (Fig. 59). This will ensure that no piston-to-valve contact occurs upon installation of cylinder head in the event of camshaft rotation.
5. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
Fig. 60
6. Before installing cylinder head bolts, the threads should be oiled with engine oil. The 4 shorter bolts 164 mm (6.45 inch), are to be installed in positions 7, 8, 9, and 10 (Fig. 60).
7. Tighten the cylinder head bolts in the sequence shown in (Fig. 60). Using the 4 step torque method, tighten according to the following values:
- First All to 34 Nm (25 ft. lbs.)
- Second All to 68 Nm (50 ft. lbs.)
- Third All to 68 Nm (50 ft. lbs.)
- Fourth Turn an additional 1/4 Turn. Do not use a torque wrench for this step.
8. Install cylinder head cover.
9. Install heater hose to thermostat housing connector.
10. Install heater tube to cylinder head attaching fasteners.
11. Connect cam sensor and coolant temperature electrical connectors.
12. Connect Crankcase Closed Ventilation (CCV) hose to cylinder head cover.
13. Install ignition coil and spark plug cables. Connect coil electrical connector.
14. Install intake manifold.
15. Install upper radiator hose.
16. Install ground wire to cylinder head.
17. Install coolant recovery container.
18. Connect fuel line to fuel rail.
19. Install rear timing belt cover, camshaft sprocket, and timing belt tensioner and timing belt.
20. Install front timing belt cover.
21. Install engine mount bracket.
22. Position engine and install right side engine mount to engine mount bracket bolt. Tighten bolt to 118 Nm (87 ft. lbs.). Remove jack from beneath engine.
23. Install power steering pump assembly.
24. Install power steering hose support clip and ground strap to engine mount bracket.
25. Install upper torque strut.
26. Raise vehicle.
27. Install lower torque strut.
28. Install crankshaft damper.
29. Install accessory drive belts.
30. Install right side splash shield and front wheel.
31. Install exhaust pipe to exhaust manifold flange.
32. Lower vehicle and fill cooling system. Refer to Cooling System for procedure. Cooling System Filling
33. Connect negative cable to battery.
34. Perform camshaft and crankshaft timing relearn procedure as follows:
- Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel; near the steering column.
- Turn the ignition switch on and access the "miscellaneous" screen.
- Select "re-learn cam/crank" option and follow directions on DRB screen.