Cylinder Head Assembly: Service and Repair
REMOVAL - CYLINDER HEAD
1. 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 vehicle on hoist.
5. Drain cooling system.
6. Disconnect exhaust pipe from exhaust manifold.
7. Remove right front wheel.
8. Remove accessory drive belt splash shield.
9. Remove generator belt.
10. Remove crankshaft vibration damper.
11. Remove lower torque strut.
12. Lower vehicle and remove upper torque strut.
13. Remove 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 front timing belt cover.
20. Rotate engine until timing marks are aligned.
21. Remove timing belt.
22. Remove timing belt tensioner/bracket assembly.
23. Remove camshaft sprocket.
24. Remove rear timing belt cover.
25. Disconnect fuel line at fuel rail.
26. Remove coolant recovery container.
27. Remove ground strap to cylinder head.
28. Remove upper radiator hose.
29. Remove 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 Engine Coolant Temperature (ECT) sensor 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. 14).
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. Refer to Engine/Service and Repair/Procedures/Standard Procedures/Engine Gasket Surface Preparation. Engine Gasket Surface Preparation
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. 15).
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. 16). Replace guides if they are not within specification.
5. Check valve guide height (Fig. 17).
INSTALLATION - CYLINDER HEAD
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. 18).
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. 19). 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. 20).
7. Tighten the cylinder head bolts in the sequence shown in (Fig. 20). Using the 4 step torque turn method, tighten according to the following values:
First:
^ All bolts to 34 Nm (25 ft. lbs.)
Second:
^ Bolts 1-6 to 68 Nm (50 ft. lbs.)
^ Bolts 7-10 to 49 Nm (35 ft. lbs.)
Third:
^ Bolts 1-6 to 68 Nm (50 ft. lbs.)
^ Bolts 7-10 to 49 Nm (35 ft. lbs.)
CAUTION: Do not use a torque wrench for the Fourth step.
Fourth:
^ Tighten all bolts in the specified sequence an additional 90° (1/4 Turn)
8. Install 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 Engine Coolant Temperature (ECT) sensor electrical connectors.
12. Connect make-up air hose to cylinder head cover.
13. Install ignition coil and spark plug cables. Connect coil electrical connector.
14. Install intake manifold.
15. Install upper radiator hose.
16. Install ground strap to cylinder head.
17. Install coolant recovery container.
18. Connect fuel line to fuel rail.
19. Install rear timing belt cover.
20. Install timing belt tensioner/bracket assembly.
21. Install camshaft sprocket.
22. Install timing belt.
23. Install front timing belt cover.
24. Install engine mount bracket.
25. Position engine and install right side engine mount to engine mount bracket through bolt. Tighten bolt to 118 Nm (87 ft. lbs.). Remove jack from beneath engine.
26. Install power steering pump assembly.
27. Install power steering hose support clip and ground strap to engine mount bracket.
28. Install upper torque strut.
29. Raise vehicle on hoist.
30. Install lower torque strut.
31. Install crankshaft vibration damper.
32. Install accessory drive belts.
33. Install accessory drive belt splash shield and front wheel.
34. Connect exhaust pipe to exhaust manifold. Tighten fasteners to 23 Nm (200 inch lbs.).
35. Lower vehicle and fill cooling system.
36. Connect negative cable to battery.
37. Perform torque strut adjustment procedure.