Removal and Installation
REMOVAL
Cylinder Head Assembly
1. Perform fuel system pressure release procedure before attempting any repairs.
2. Disconnect battery negative cable from auxiliary jumper terminal.
3. Drain cooling system.
4. Remove air cleaner inlet duct and air cleaner upper housing, disconnect all vacuum lines, electrical wiring and fuel lines from throttle body.
5. Remove throttle linkage.
6. Remove accessory drive belts. Refer to Cooling System for procedure.
7. Remove power brake vacuum hose from intake manifold.
8. Raise vehicle and remove exhaust pipe from manifold.
9. Remove power steering fluid reservoir and set aside.
10. Disconnect ignition coil wiring connector and remove ignition coil from engine.
11. Remove cylinder head cover.
12. Remove cam sensor and fuel injectors wiring connectors.
13. Remove intake manifold.
14. Remove timing belt, camshaft sprocket and rear timing belt cover.
15. Remove rocker arm shaft assemblies.
Fig. 60
16. Remove cylinder head bolts in reverse order of tightening sequence (Fig. 60).
17. Carefully lift cylinder head from block.
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 bolts 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
CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper.
Fig. 58
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(tm) 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(tm) 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.
6. Before installing the cylinder head bolts, the threads should be oiled with engine oil. The 4 short bolts 110 mm (4.330 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 image. 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.
Fig. 61
8. Install rocker shaft assemblies in correct order as removed. Tighten rocker arm shaft bolts in sequence shown in (Fig. 61) to 28 Nm (250 in. lbs.).
9. Install rear timing belt cover, camshaft sprocket, and timing belt.
10. Install intake manifold.
11. Connect electrical connectors to cam sensor and fuel injectors.
12. Install cylinder head cover and tighten fasteners to 12 Nm (105 in. lbs.).
13. Connect PCV and make-up air hose to cylinder head cover.
14. Install power steering reservoir.
15. Install ignition coil and connect wiring connector.
16. Connect power brake booster vacuum hose to intake manifold.
17. Connect throttle linkage to throttle body.
18. Connect all vacuum lines and electrical wiring connectors.
19. Install air cleaner inlet duct and upper air cleaner housing.
20. Raise vehicle on hoist and connect exhaust system to exhaust manifold.
21. Lower vehicle and connect negative cable to auxiliary battery terminal.
22. With the DRB scan tool use ASD Fuel System Test to pressurize fuel system. Check for fuel leaks.
CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.