Cylinder Head Assembly: Service and Repair
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 the vehicle on hoist.
5. Drain the cooling system.
6. Remove exhaust pipe from the exhaust manifold.
7. Remove right front wheel.
8. Remove right side splash shield.
9. Remove generator belt.
10. Remove the crankshaft vibration damper.
11. Remove the lower torque strut.
12. Lower vehicle and remove upper torque strut.
13. Remove the 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 the engine mount bracket. This procedure may require additional raising/lowering of engine until bracket will clear engine components.
19. Remove the front timing belt cover.
20. Rotate engine until timing marks are aligned.
21. Remove the timing belt.
22. Remove the timing belt tensioner.
23. Remove the camshaft sprocket.
24. Remove rear timing belt cover.
25. Disconnect fuel line at fuel rail.
26. Remove coolant recovery container.
27. Remove the ground wire to cylinder head.
28. Remove the radiator upper hose.
29. Remove the intake manifold.
30. Disconnect ignition coil electrical connector.
31. Remove ignition coil and spark plug cables from engine.
32. Remove make-up air hose from cylinder head cover.
33. Disconnect cam sensor and coolant temperature electrical connectors.
34. Remove heater tube to cylinder head attaching fasteners.
35. Remove heater hose from thermostat housing connector.
36. Remove cylinder head cover.
37. Remove cylinder head bolts.
38. Remove cylinder head and gasket (Fig. 13).
CLEANING
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.
Remove all gasket material from cylinder head and block. Be careful not to gouge or scratch the aluminum head sealing surface.
Clean all engine oil passages.
INSPECTION
1. Cylinder head must be flat within 0.1 mm (0.004 inch) (Fig. 14).
2. Inspect camshaft bearing journals for scoring.
3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
4. Using a small hole gauge and a micrometer, measure valve guides in 3 places top, middle and bottom (Fig. 15). Replace guides if they are not within specification.
5. Check valve guide height (Fig. 16).
INSTALLATION
Examining Cylinder Head Bolts
NOTE: The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolt(s) should be replaced (Fig. 17).
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.
1. Clean the cylinder head and cylinder block sealing surfaces.
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.
4. Position crankshaft sprocket to TDC, then rotate crankshaft until mark is three teeth before TDC (Fig. 18). 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.
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. 19).
7. Tighten the cylinder head bolts in the sequence shown in (Fig. 19). 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 the 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 make-up air hose to cylinder head cover.
13. Install the ignition coil and spark plug cables. Connect coil electrical connector.
14. Install the intake manifold.
15. Install the radiator upper hose.
16. Install the ground wire to the cylinder head.
17. Install the coolant recovery container.
18. Connect the fuel line to fuel rail.
19. Install the rear timing belt cover, camshaft sprocket, and timing belt tensioner and timing belt.
20. Install the front timing belt cover.
21. Install the 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 the upper torque strut.
26. Raise the vehicle.
27. Install the lower torque strut.
28. Install the crankshaft vibration damper.
29. Install the 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.
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.