300, Magnum, 2005

Valve Covers

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Removal & Installation



2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. For the left side cylinder head cover:
    1. Disconnect electrical connectors from ignition coils.
    2.  
    3. Remove ground strap from cylinder head cover stud and disconnect capacitor connector. Reposition electrical harness.
    4.  
    5. Disconnect electrical harness retaining clips from cylinder head cover studs. Reposition electrical harness.
    6.  
    7. Remove make up air hose.
    8.  
    9. Remove fastener attaching ignition coil capacitor.
    10.  
    11. Remove ignition coils.
    12.  

  4.  
  5. Loosen all cylinder head cover fasteners.
    NOTE
    Cylinder head cover attaching bolts are captured to the cover.


    WARNING
    Make certain the double ended studs in the center of the cylinder head cover are loose before attempting to remove cover.

    1. Remove cylinder head cover.
    2.  

  6.  
  7. For the right side cylinder head cover:
    1. Disconnect electrical connectors from ignition coils.
    2.  
    3. Disconnect capacitor electrical connector.
    4.  
    5. Remove PCV hose from cylinder head cover grommet.
    6.  
    7. Remove ground strap from cylinder head cover stud.
    8.  
    9. Disconnect electrical harness retaining clips from cylinder head cover studs. Reposition electrical harness.
    10.  
    11. Remove fastener attaching ignition coil capacitor.
    12.  
    13. Remove ignition coils.
    14.  
    15. Remove foam insulator.
    16.  

  8.  
  9. Loosen all cylinder head cover fasteners.
    NOTE
    Cylinder head cover attaching bolts are captured to the cover.


    WARNING
    Make certain the double ended studs in the center of the cylinder head cover are loose before attempting to remove cover.

  10.  
  11. Remove cylinder head cover.
  12.  

To install:

  1. For the left side cylinder head cover:
    1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gaskets as necessary.
    2.  
    3. Install cylinder head cover and hand start all fasteners. Verify that all double-ended studs are in the correct locations.
    4.  
    5. Tighten cylinder head cover attaching bolts and double-ended studs to 105 inch lbs. (12 Nm).
    6.  
    7. Install ignition coils.
    8.  
    9. Install ignition coil capacitor and fastener.
    10.  
    11. Install ground strap to cylinder head cover stud.
    12.  
    13. Connect all electrical connectors and harness clips.
    14.  
    15. Connect make up air hose.

      Click image to see an enlarged view

      Fig. Cylinder head cover installation-2.7L engine

    16.  

  2.  
  3. For the right cylinder head cover:
    1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gaskets as necessary.
    2.  
    3. Install cylinder head cover and hand start all fasteners. Verify that all double-ended studs are in the correct locations.
    4.  
    5. Tighten cylinder head cover attaching bolts and double-ended studs to 105 inch lbs. (12 Nm).
    6.  
    7. Install ignition coils.
    8.  
    9. Install ignition coil capacitor and fastener.
    10.  
    11. Connect ground strap to cylinder head cover stud.
    12.  
    13. Connect PCV hose to cylinder head cover grommet.
    14.  
    15. Connect all electrical connectors and harness clips.
    16.  
    17. Install foam insulator on top of cylinder head cover.
    18.  

  4.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. For the left cylinder head cover:
    1. Disconnect and remove the three ignition coils.
    2.  
    3. Remove the ground strap/resistor retaining bolt from the cylinder head cover.
    4.  
    5. Lift up on the wire harness track retaining tabs.
    6.  
    7. Completely loosen the cylinder head cover retaining bolts and remove the cylinder head cover.
    8.  

  4.  
  5. For the right cylinder head cover:
    1. Disconnect and remove the three ignition coils.
    2.  
    3. Lift up on the wire harness track retaining tabs.
    4.  
    5. Remove the ground strap retaining bolt from the cylinder head cover.
    6.  
    7. Completely loosen the cylinder head cover retaining bolts and remove the cylinder head cover

      Click image to see an enlarged view

      Fig. Cylinder head cover removal-3.5L engine



      Click image to see an enlarged view

      Fig. Cylinder head cover gasket (1) and seals (2)-3.5L engine



      Click image to see an enlarged view

      Fig. Spark plug tube seal (2) replacement using tool MD-998306 (1)-3.5L engine

    8.  

  6.  

To install:

  1. To replace spark plug tube seals:
    1. Using a suitable pry tool, carefully remove tube seals .
    2.  
    3. Position new seal with the part number on seal facing cylinder head cover.
    4.  
    5. Install seals using Special Tool MD-998306.
    6.  

  2.  
  3. For the right cylinder head cover:
    1. Clean cylinder head and cover mating surfaces. Inspect and replace gasket and seals as necessary.
    2.  
    3. Install cylinder head cover bolts and tighten to 105 inch lbs. (12 Nm).
    4.  
    5. Install the ground strap retaining bolt to the cylinder head cover.
    6.  
    7. Install the wire harness track.
    8.  
    9. Install the ignition coils. Tighten mounting screws to 60 inch lbs. (6.7 Nm).
    10.  
    11. Connect the ignition coil electrical connectors.
    12.  

  4.  
  5. For the left cylinder head cover:
    1. Clean cylinder head and cover mating surfaces. Inspect and replace gasket and seals as necessary.
    2.  
    3. Install cylinder head cover and bolts. Tighten to 105 inch lbs. (12 Nm).
    4.  
    5. Position the wiring harness on the cylinder head cover.
    6.  
    7. Re-clip the wire harness track retaining tabs into the cover.
    8.  
    9. Install the ground strap/resistor retaining bolt onto the cylinder head cover.
    10.  
    11. Install the ignition coils. Tighten mounting screws to 60 inch lbs. (6.7 Nm)
    12.  

  6.  

5.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. For the right side cylinder head cover:
    1. Disconnect electrical connectors from ignition coils.
    2.  
    3. Disconnect capacitor electrical connector.
    4.  
    5. Remove PCV hose from cylinder head cover grommet.
    6.  
    7. Remove ground strap from cylinder head cover stud.
    8.  
    9. Disconnect electrical harness retaining clips from cylinder head cover studs. Reposition electrical harness.
    10.  
    11. Remove fastener attaching ignition coil capacitor.
    12.  
    13. Remove ignition coils.
    14.  
    15. Remove foam insulator.
    16.  

  4.  
  5. Loosen all cylinder head cover fasteners.
    NOTE
    Cylinder head cover attaching bolts are captured to the cover.


    WARNING
    Make certain the double ended studs in the center of the cylinder head cover are loose before attempting to remove cover.

  6.  
  7. Remove cylinder head cover.
  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head cover bolt loosening/tightening sequence-5.7L engine



Click image to see an enlarged view

Fig. Cylinder head cover (1), cover gasket (2), studs (3), cylinder head (4), head gasket (5)-5.7L engine


NOTE
The gasket may be used again, provided no cuts, tears, or deformation has occurred.


WARNING
Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur.


WARNING
DO NOT allow other components including the wire harness to rest on or against the engine cylinder head cover. Prolonged contact with other objects may wear a hole in the cylinder head cover.

  1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
  2.  
  3. Install cylinder head cover and hand start all fasteners. Verify that all double ended studs are in the correct location and install left and right ground straps.
    NOTE
    The ground straps must be installed in the same location as removed. The covers are machined to accept the ground straps in those locations only. The right hand ground strap is located on the front inboard stud. The left hand ground strap is located on the rear inboard stud.

  4.  
  5. Tighten cylinder head cover bolts and double ended studs to 70 inch lbs. (8 Nm). Begin torque sequence in the middle of head cover and torque bolts moving outward in a crisscross pattern from top to bottom.
  6.  
  7. Install ignition coil on plug, and torque fasteners to 105 inch lbs. (12 Nm).
  8.  
  9. Connect, ignition coil electrical connectors.
  10.  
  11. Install PCV hose.
  12.  
  13. Connect battery negative cable.
  14.  

 
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