Installation

INSTALLATION





The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced (Fig. 13).

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 must be replaced.

CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.

1. Clean sealing surfaces of cylinder head and block.

CAUTION: Ensure that the correct head gaskets are used and are oriented correctly on cylinder block. The 3.5L engine head gaskets have perfectly round combustion sealing rings. The 3.2L engine does NOT have perfectly round combustion sealing rings.





2. Install head gasket over locating dowels. Ensure the gasket is installed on the correct side of engine (Fig. 14).
3. Install cylinder head over locating dowels.
4. Before installing the bolts, lubricate the threads with engine oil.





5. Tighten the cylinder head bolts in the sequence shown in (Fig. 15). Using the 4 step torque-turn method, tighten according to the following torque values:
^ Step 1: All to 61 Nm (45 ft. lbs.)
^ Step 2: All to 88 Nm (65 ft. lbs.)
^ Step 3: All (again) to 88 Nm (65 ft. lbs.)
^ Step 4: ±90° Turn Do not use a torque wrench for this step.
6. Bolt torque after 90� turn should be over 122 Nm (90 ft. lbs.) in the tightening direction. If not, replace the bolt.
7. Clean right rear timing belt cover O-ring sealing surfaces and grooves (Fig. 11). Lubricate new O-rings with Mopar Dielectric Grease or equivalent to facilitate assembly.
8. Install rear timing belt covers (Fig. 10) and (Fig. 11). Tighten bolts to specified torque:
^ M10 - 54 Nm (40 ft. lbs.)
^ M8 - 28 Nm (20 ft. lbs.)
^ M6 - 12 Nm (105 in. lbs.)
9. Install camshaft sprockets and timing belt.
10. Install front timing belt covers.
11. Install crankshaft vibration damper.
12. Install upper and lower intake manifold.
13. Connect catalytic converter to exhaust manifold using a new V-band clamp(s). Tighten clamp to 10 Nm (100 in. lbs.).
14. Fill cooling system.
15. Connect negative cable to remote jumper terminal