Cylinder Head Assembly: Service and Repair

REMOVAL
1. Perform fuel pressure release procedure before attempting any repairs.
2. Disconnect negative cable from remote battery jumper terminal.
3. Drain cooling system.
4. Remove crankshaft vibration damper.
5. Remove front timing belt covers.
6. Remove camshaft sprockets.
7. Remove upper and lower intake manifold.
8. Remove V-Band clamp(s) at exhaust manifold to catalytic converter pipe connection.

NOTE: Do not reuse V-Band Clamp.






9. Remove rear timing belt cover to cylinder head fasteners (Fig. 10). Remove the rear covers.





10. The right side rear timing belt cover has O-rings to seal the water pump passages to cylinder block (Fig. 11). Do not reuse O-rings.





11. Remove cylinder head bolts in REVERSE of tightening sequence (Fig. 15).
12. Remove cylinder head(s).


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.

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. Before cleaning, check for leaks, damage and cracks.
2. Clean cylinder head and oil passages.





3. Check cylinder head for flatness (Fig. 12).
4. Cylinder head must be flat within:
- Standard dimension = less than 0.05 mm (0.002 in.)
- Service Limit = 0.2 mm (0.008 in.)
- Grinding Limit = Maximum of 0.2 mm (0.008 in.) is permitted.


CAUTION: 0.20 mm (0.008 in.) MAX is a combined total dimension of the stock removal limit from cylinder head and block top surface (Deck) together.



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.