Cylinder Head Assembly: Service and Repair

REMOVAL
1. Disconnect the negative cable from the battery.
2. Drain cooling system.

Spark Plug Wire Heat Shields (Left Side Shown):

3. Remove the heat shields.
4. Remove the intake manifold-to-generator bracket support rod. Remove the generator.
5. Remove closed crankcase ventilation system.
6. Disconnect the evaporation control system.
7. Remove the air cleaner.
8. Perform the Fuel System Pressure release procedure (refer to Powertrain Management). Disconnect the fuel line.
9. Disconnect accelerator linkage and if so equipped, the speed control and transmission kickdown cables.

Coil Pack And Bracket:

10. Remove coil pack and bracket.
11. Disconnect the coil wires.
12. Disconnect heat indicator sending unit wire.
13. Disconnect heater hoses and bypass hose.
14. Remove upper intake manifold and throttle body as an assembly.
15. Remove cylinder head covers and gaskets.
16. Remove the EGR tube. Discard the gasket, for right side only.
17. Remove lower intake manifold. Discard the flange side gaskets and the front and rear cross-over gaskets.
18. Disconnect exhaust pipe from exhaust manifold.
19. Remove exhaust manifolds and gaskets.
20. Remove rocker -arm assemblies and push rods. Identify to ensure installation in original locations.
21. Remove the head bolts from each cylinder head and remove cylinder heads. Discard the cylinder head gasket.
22. Remove spark plugs.

INSTALLATION
1. Position the new cylinder head gaskets onto the cylinder block.
2. Position the cylinder heads onto head gaskets and cylinder block.

Cylinder Head Bolt Tightening Sequence:

3. Tighten the cylinder head bolts in two steps:
^ Step 1-Tighten all cylinder head bolts, in sequence, to 58 Nm (43 ft. lbs.) torque.
^ Step 2-Tighten all cylinder head bolts, in sequence, to 143 Nm (105 ft. lbs.) torque.

CAUTION: When tightening the rocker arm bolts, make sure the piston in that cylinder is NOT at TDC. Contact between the valves and piston could occur.

4. Install push rods and rocker arm assemblies in their original position. Tighten the bolts to 28 Nm (21 ft. lbs.) torque.

Intake Manifold Flange Gasket Alignment:

5. Install the side intake manifold gaskets. Be sure that the locator dowels are positioned in the head.

Intake Manifold-to-Block Seals:

6. Peel off the protective paper (blue-rear and brown-front) and press firmly onto the block. BE SURE THE BLOCK IS OIL FREE. Aligning slots in end seals with notches in intake manifold gaskets.

Mopar Silicone Rubber Adhesive Sealant Application Locations:

7. Insert Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent, into the four corner pockets. Fill the pocket, but DO NOT overfill.
8. The lower intake manifold MUST be installed within 3 minutes of sealant application. Carefully lower intake manifold into position on the cylinder block and cylinder heads. After intake manifold is in place, inspect to make sure seals and gaskets are in place.
9. Finger start all bolts, alternate one side to the other.
10. Tighten the lower intake manifold bolts to 54 Nm (40 ft. lbs.) torque.
11. Using a new gasket, position the upper intake manifold onto the lower intake manifold.
12. Tighten upper intake manifold bolts to 22 Nm (16 ft. lbs.) torque.
13. Install the exhaust manifolds and new gaskets. Tighten the bolts and stud bolts to 22 Nm (16 ft. lbs.) torque.
14. Install exhaust pipe to the exhaust manifold. Tighten the bolts to 34 Nm (25 ft. lbs.) torque.
15. Using a new gasket, position the EGR tube to the intake manifold and the exhaust manifold. Tighten the EGR tube nut to 34 Nm (25 ft. lbs.) torque. Tighten the bolts to 20 Nm (174 inch lbs.) torque.
16. Install the heat shields and the washers. Make sure that heat shields tabs hook over the exhaust gasket. Tighten the nuts to 15 Nm (132 inch lbs.) torque.
17. Adjust spark plugs to specifications. Install the plugs and tighten to 41 Nm (30 ft. lbs.) torque.
18. Install coil packs and bracket. Tighten the bracket bolts to 21 Nm (190 inch lbs.) torque. Connect the coil wires.
19. Connect heat indicator sending unit wire.
20. Connect the heater hoses and bypass hose.
21. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
22. Install the fuel line.
23. Install the generator and drive belt. Tighten generator mounting bolt to 41 Nm (30 ft. lbs.) torque. Tighten the adjusting strap bolt to 23 Nm (200 inch lbs.) torque.
24. Install the intake manifold-to-generator bracket support rod. Tighten the bolts to 41 Nm (30 ft. lbs.) torque.
25. The cylinder head cover gasket can be used again. Install the gasket onto the head rail. For the left side the number tab is at the front of engine with the number up. For the right side the number tab is at the rear of engine with the number up.

CAUTION: The cylinder head cover fasteners have a special plating. DO NOT use alternative fasteners.

26. Position the cylinder head cover onto the gasket. Install the stud bolts and hex head bolts in the proper positions. Tighten the stud bolts and the bolts to 16 Nm (144 inch lbs.) torque.
27. Install closed crankcase ventilation system.
28. Connect the evaporation control system.
29. Install the air cleaner.
30. Fill cooling system.
31. Connect the negative cable to the battery.
32. Check for leaks (fuel, oil, antifreeze, etc.).