Cylinder Head Assembly: Service and Repair
Pre-removal Operation and Draining:1. Engine Coolant.
2. Air Intake Manifold.
3. Turbocharger.
4. Exhaust Manifold.
5. Timing Belt.
Removal steps
Figure 1 Cylinder Head Removal:
Note: The following numbers are both sequential operations and act as the index for the image figure 1.
1. Pipe assembly.
2. Blow-by hose.
3. Center cover (Front bank).
4. Spark plug cable.
5. Rocker cover.
6. Intake camshaft sprocket:
Caution: Locking the camshaft sprocket with a tool damages the sprocket.
a. Using a wrench, hold the camshaft at its hexagon and remove the camshaft sprocket bolt.
b. Remove the camshaft sprockets.
7. Timing belt rear cover (Center).
8. Ignition coil.
9. Connection of heater hose.
10. Connection of water hoses.
11. Connection of radiator hose.
Thermostat Housing:
12. Thermostat housing.
13. Connection of water inlet pipe (Front bank).
14. Cylinder head assembly:
Using a 10 mm hex wrench, remove the cylinder head assembly.
15. Cylinder head gasket:
Use a scraper to clean the gasket surface of the cylinder head assembly.
Caution: Take care that no foreign material gets into the cylinder, coolant passages or oil passages.
Installation Steps
Note: The following numbers are reverse of installation and also act as the index for the image figure 1.
Head Gasket Id:
15. Cylinder head gasket:
a. Make sure that the gasket has the proper identification mark for the engine.
b. Lay the cylinder head gasket on the cylinder block with the identification mark at the front top.
14. Cylinder head assembly:
Caution: Install the head bolt washers with shear droop upward as shown in the illustration.
Cylinder Head Torque Sequence:
a. Using a 10 mm hex wrench and a torque wrench, tighten the bolts to the specified torque in the order shown in the illustration. (in two or three cycles)
b. Back off the bolts once and tighten them to the specified torque as shown in step (a).
13. Connection of water inlet pipe (Front bank).
Thermostat Housing:
12. Thermostat housing.
11. Connection of radiator hose.
10. Connection of water hoses.
9. Connection of heater hose.
8. IgnitIon coil.
7. Timing belt rear cover (Center).
6. Intake camshaft sprocket:
Using a wrench, hold the camshaft at its hexagon and tighten the bolt to specification.
Caution: Locking the camshaft sprocket with a tool damages the sprocket.
Note: Sealant: MOPAR Part No. 4318034 or equivalent.
Rocker Cover Torque Sequence:
5. Rocker cover.
Tighten the rocker cover bolts in the order shown in the illustration.
Note:
a. Only No.5 bolt in the rear bank differs from other bolts in length.
Rear bank No.5 bolt 20 mm ( 0.79 in.)
Except rearbank No.5 bolt 10 mm( 0.39in.)
b. Bolts are color-coded for the front and rear banks as follows:
Front bank Black
Rearbank Green
c. When the rocker cover gasket has been replaced, tighten bolts in this order, and then retighten bolts 1 to 6 to 4 Nm (2.9 ft/lbs.).
4. Spark plug cable.
3. Center cover (Front bank).
2. Blow-by hose.
1. Pipe assembly.
Post-installation Operation and Supplying:
1. Timing Belt.
2. Exhaust Manifold.
3. Turbocharger.
4. Air Intake Manifold.
5. Engine Coolant.
Adjustment:
- Accelerator Cable
- Engine Adjustment - Check and adjust the following as required:
- Drive belts tension.
- Ignition timing.