Service Procedure

A. Important: No service is required for vehicles with existing RTV Sealant Installation.

Some involved vehicles may already have been equipped with the new cylinder head cover and RTV sealant under recently issued Technical Service Bulletin (TSB) No. 09-17-89.

These vehicles can be visually identified by looking for gasket tabs extending up through slots in the sealing surface on the long sides of the valve cover. If there are no gasket tabs or slots in this area new cover has already been installed.

B. Replacement of Valve Cover and Gasket

1. Disconnect the negative battery lead.

2. Remove the air cleaner and air intake tube.

3. Disconnect the throttle cable(s) from the throttle body and bracket and move the cable(s) aside (not required on Dakota truck).

Figure 1 -- All Except Dakota Truck:

Figure 2 -- Dakota Truck Only:

4. Remove fuel tube/wiring bracket fasteners. (See Figures 1 and 2.)
5. Remove upper timing belt cover.

Note: Retain tube bracket and timing cover stud nuts for reassembly.

6. Disconnect PCV hose from cylinder head cover.

7. Remove existing cylinder head cover, gasket and aside for parts return.

8. Clean cylinder head rail gasket surface with Mopar Parts Cleaner PN 4318037 or equivalent.

Figure 3:

9. Apply RTV sealant to cylinder head rail (Figure 3).
10. Attach the two supplied cylinder head cover end seals to new cover.

11. Install the cylinder head cover assembly on the cylinder head, using the
4 supplied studs with washers at each corner of the cylinder head. Install the 5 supplied screws with washers in the remaining holes. Install original oil filler cap on new cover.

Important: Be sure to use the fasteners from the parts package at all locations. These fasteners have washers and a different coating on them for improved torque retention.

Figure 4:

Caution: Be sure that the engine wiring harness is routed clear of the studs and cylinder head cover edges to avoid possible chafing (Figure 4).
12. Tighten the cylinder head cover fasteners to 105 in.lbs. (12 N-m) torque.

13. Reconnect PCV hose.

Figure 1 -- All Except Dakota Truck:

Figure 2 -- Dakota Truck Only:

14. Reinstall the timing belt cover and the fuel tube/wiring bracket fasteners (Figures 1 and 2). Tighten the fasteners to 40 in.lbs. (4 N-m).

15. Reconnect throttle cable(s) to the bracket and throttle body.

16. Reinstall air cleaner and air intake tube.

17. Reconnect negative battery lead.

18. Start engine and inspect for leaks.