Cylinder Head - Installation

INSTALLATION - CYLINDER HEAD

NOTE: Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.

NOTE: The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced.

Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2), the bolt should be replaced.

CAUTION: Always replace the variable valve timing filter screen (3) when servicing the head gasket or engine damage could result.

1. Replace the variable valve timing filter screen (3).

NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil.

NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.

2. Place two pea size dots of Mopar(R) engine sealant RTV or equivalent (1) on cylinder block as shown.

3. Position the new cylinder head gasket on engine block with the part number facing up. Ensure gasket is seated over the locating dowels in block.
4. Place two pea size dots of Mopar(R) engine sealant RTV or equivalent (1) on cylinder head gasket as shown.

NOTE: The head must be installed within 15 minutes before the RTV skins.

5. Position cylinder head onto engine block.

CAUTION: This engine was built with 2 different style cylinder head bolts. Each style bolt requires a different torque value. The bolts can be identified by the short bolt head (1) and the long bolt head (2).

6. Measure the bolt head from the washer to the top of the bolt head. The short bolt head (1) measures 8 mm (5/16") and the long bolt head (2) measures 13 mm (1/2").
7. Identify whether your engine has the short head design (1) or the long head design (2).

NOTE: The front two cylinder head bolts do not have captured washers. The washers must be installed with the bevel up towards the bolt head.

8. Install washers (1) for the front two cylinder head bolts.

9. Before installing the bolts, the threads should be lightly coated with engine oil.
10. Install the cylinder head bolts and tighten in the sequence shown.

11. If your bolt has the short head (1), use the following torque specifications:
- First: All to 30 Nm (25 ft. lbs.)
- Second: All to 61 Nm (45 ft. lbs.)
- Third: All to 61 Nm (45 ft. lbs.)
- Fourth: All an additional 90°

CAUTION: Do not use a torque wrench for the Fourth step.

12. If your bolt has the long head (2), use the following torque specifications:
- First: All to 30 Nm (25 ft. lbs.)
- Second: All to 73 Nm (54 ft. lbs.)
- Third: All to 73 Nm (54 ft. lbs.)
- Fourth: All an additional 90°

CAUTION: Do not use a torque wrench for the Fourth step.

13. Clean excess RTV from timing chain cover sealing surface.
14. Install camshafts.Camshaft - Installation.

15. Install cylinder head cover Cylinder Head Cover - Installation.
16. Install exhaust manifold Exhaust Manifold - Installation.
17. Install ground strap (1) at right rear of cylinder head.

18. Install coolant adapter (3) with new seals.
19. Connect coolant hoses.
20. Connect purge hose (4).

21. Install intake manifold.
22. Install intake manifold bolts and tighten to 24 Nm (18 ft. lbs.).

23. Install upper radiator hose retaining bracket bolt (1).

24. Install timing chain (2)Timing Chain & Sprockets - Installation.
25. Install timing chain coverTiming Cover - Installation.

26. Remove coils from cylinder head cover.
27. Install cylinder head coverCylinder Head Cover - Installation.

28. Connect cam sensor wiring connector.
29. Install spark plugs and tighten to 27 Nm (20 ft. lbs.).
30. Install ignition coils (1) and tighten to 8 Nm (70 in. lbs.).

31. Install power steering pump reservoir (2).
32. Install coolant recovery reservoir (1)
33. Install accessory drive belts Accessory Drive Belt - Installation.
34. Connect engine coolant temperature sensor connector.

35. Connect coolant hoses to coolant adapter (3).
36. Connect heater hoses to thermostat housing (3).
37. Connect coolant temperature sensor (1) and capacitor (2) electrical connectors.
38. Install heater tube support bracket to cylinder head.

39. Install fastener attaching dipstick tube to lower intake manifold.
40. Connect coil (1) and injector (4) electrical connectors.
41. Install fuel rail.
42. Connect fuel supply line quick-connect (3) at the fuel rail assembly Service and Repair.
43. Fill cooling system Service and Repair.

44. Connect negative battery cable (1).

45. Install clean air hose (1) and air cleaner housing (2)Air Cleaner Housing - Installation.

46. Install new oil filter and fill engine with oil.
47. Start engine and check for leaks.
48. Install engine cover (1).