300M, Concorde, Intrepid, LHS, 1998-2004

Cylinder Head

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Removal & Installation



2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Place shop rags in the openings to prevent debris from entering the engine.



    Negative battery cable
     
    Accessory drive belts
     
    Crankshaft damper
     
    Intake plenum, lower intake manifold and exhaust manifold
     



    Valve and timing chain covers
     
    Coolant connections for the cylinder heads
     

  8.  
  9. Rotate the crankshaft until the crankshaft timing mark aligns with the timing mark on the oil pump.
    WARNING
    Be sure the head bolts 9-11 are removed before attempting to remove the cylinder head, the head and/or block may be damaged.



    Primary timing chain
     
    Camshaft bearing caps, gradually, in the reverse order of the tightening sequence
     
    Camshafts
     



    Cylinder head bolts in reverse order of installation starting with bolts 11-9, then 8-1
     
    Cylinder head(s)
     

  10.  

To install:

Click image to see an enlarged view

Fig. Camshaft bolt tightening sequence-2.7L engine



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.7L engine

  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean the oil passages thoroughly.
  2.  
  3. Place a new head gasket on the cylinder block over the locating dowels.
  4.  
  5. Inspect the cylinder head bolts for necking (stretching) by holding a straightedge against the threads of each bolt. If all of the threads are not contacting the straightedge, the bolt should be replaced. New head bolts are recommended.
    WARNING
    Due to the cylinder head bolt torque method used, it is imperative that the bolt threads be inspected for necking (stretching) prior to installation. If the threads are necked down, the bolt should be replaced. Failure to do so may result in parts failure or damage.

  6.  
  7. Lubricate the bolt threads with clean engine oil, then install them.
  8.  
  9. Torque the head bolts in the sequence shown in the illustration, utilizing the following steps and tightening values:
    1. Step 1: bolts 1 through 8: 35 ft. lbs. (48 Nm).
    2.  
    3. Step 2: bolts 1 through 8: 55 ft. lbs. (75 Nm).
    4.  
    5. Step 3: bolts 1 through 8: 55 ft. lbs. (75 Nm).
    6.  
    7. Step 4: bolts 1 through 8: plus 90 degree turn using a torque angle meter.
    8.  
    9. Step 5: bolts 9 through 11: 21 ft. lbs. (28 Nm).
    10.  

  10.  
  11. Install or connect the following:

    Camshafts, timing chain and sprockets
     
    Water connections to the cylinder head
     
    Valve and timing chain covers
     
    Crankshaft damper and torque the center bolt to 125 ft. lbs. (170 Nm)
     
    Lower intake manifold and intake plenum
     
    Exhaust manifolds
     
    Accessory drive belts
     
    Negative battery cable
     

  12.  
  13. Fill the cooling system to the proper level.
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.
  16.  

3.2L & 3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  

This engine uses aluminum alloy cylinder heads. Use care when working with light alloy components. The heads are common to either cylinder bank, but in practice a cylinder head should be returned to the side of the engine from which it was removed. Removal of a cylinder head involves removal of the timing belt. Great care is required to install the belt, paying attention to all valve timing marks. Please note that camshaft removal on this engine does require the removal of the cylinder head.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Cover the lower intake manifold during service.


    NOTE
    Mark the timing belt running direction for installation. Align the camshaft sprockets with the marks on the rear covers.



    Negative battery cable
     
    Radiator and cooling fan assemblies
     
    Air cleaner assembly and intake manifold plenum
     



    Accessory drive belts
     
    Crankshaft damper using the proper puller
     
    Engine valve covers
     
    Timing belt covers
     



    Timing belt and tensioner
     

  6.  
  7. Pre-load the timing belt tensioner as follows:
    1. Place tensioner in a vise the same way it is mounted on the engine.
    2.  
    3. Slowly compress the plunger into the tensioner body.
    4.  
    5. Once the plunger is compressed, install a pin through the body and plunger to retain it in place until the tensioner is installed.
    6.  

  8.  
  9. Hold the camshaft sprocket with a 36mm box wrench, loosen and remove the sprocket retaining bolt and washer.
    NOTE
    To remove the camshaft sprocket retainer bolt while the engine is in the vehicle, it may be necessary to raise that side of the engine due to the length of the retainer bolt. The right bolt is 8.370 in. (212.6mm) long, while the left bolt is 10.0 in. (253mm) long. These bolts are not interchangeable and their original location during removal should be noted.

  10.  
  11. Remove or disconnect the following:
    NOTE
    The camshaft sprockets are not interchangeable.


    NOTE
    If the right timing belt cover is to be removed, there are O-rings located behind it for the water pump passages.



    Camshaft sprocket from the camshaft
     



    Intake manifold assembly using the recommended procedure
     
    Rear timing belt cover-to-cylinder head fasteners
     



    Cylinder head mounting bolts in the reverse order of the tightening sequence
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Remove the rear timing belt cover-to-cylinder head bolts, noting the bolt locations-3.5L engines



    Click image to see an enlarged view

    Fig. Right side belt cover, water pump and O-rings-3.5L engines

     

  12.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.5L engines

  1. Thoroughly clean and dry the mating surfaces of the head and block.
    WARNING
    When cleaning the cylinder head and block mating surfaces, do not use a metal scraper because the soft aluminum surfaces could be cut or damaged. Instead, use a scraper made of wood or plastic.

  2.  
  3. Check the cylinder head for cracks, damage or engine coolant leakage. Check the head for flatness. End-to-end, the head should be within 0.002 in. (0.051mm) normally with 0.008 in. (0.203mm) the maximum allowed out of true. The resurface limit is 0.008 in. (0.203mm) maximum, the combined total dimension of stock removal from the cylinder head, if any, and block top surface.
  4.  
  5. Place a new head gasket on the cylinder block locating dowels, being sure the gasket is on the correct side.

    Click image to see an enlarged view

    Fig. Correct positioning for the head gaskets-3.5L engines

  6.  
  7. Inspect the cylinder head bolts for necking (stretching) by holding a straightedge against the threads of each bolt. If all of the threads are not contacting the scale, the bolt should be replaced.
    WARNING
    Due to the cylinder head bolt torque method used, it is imperative that the threads of the bolts be inspected for necking prior to installation. If the threads are necked down, the bolt should be replaced. Failure to do so may result in parts failure or damage. New bolts are always recommended.

  8.  
  9. Install the cylinder head into position on the engine block and over the dowels. Install the cylinder head bolts, lubricating the threads with clean engine oil prior to installation.
  10.  
  11. Torque the cylinder head bolts using the proper sequence as follows:
    1. Step 1: torque in sequence to 45 ft. lbs. (61 Nm).
    2.  
    3. Step 2: torque in sequence to 65 ft. lbs. (88 Nm).
    4.  
    5. Step 3: torque in sequence to 65 ft. lbs. (88 Nm).
    6.  
    7. Step 4: torque in sequence an additional 1 / 4 turn by using a torque angle meter.
      NOTE
      Inspect the bolt torque after tightening. The torque should be over 90 ft. lbs. (122 Nm). If not, replace the cylinder head bolt.

    8.  

  12.  
  13. Install the rear timing belt cover bolts and torque as follows:


    1. M6 bolts: 105 inch lbs. (12 Nm).
    2.  
    3. M8 bolts: 21 ft. lbs. (28 Nm).
    4.  
    5. M10 bolts: 40 ft. lbs. (54 Nm).
    6.  

  14.  
  15. Install the intake manifold assembly and torque the bolts following the proper sequence to 21 ft. lbs. (28 Nm).
    NOTE
    The following procedure can only be used when the camshaft sprockets have been loosened or removed from the shafts.

  16.  
  17. When the camshaft sprockets are loosened or removed, the camshafts must be timed to the engine. Install the Camshaft Alignment tools 6642-A, to the rear of the cylinder heads.
  18.  
  19. Install both camshaft sprockets to the appropriate shafts. The left camshaft sprocket has the Distributorless Ignition System (DIS) pickup as part of the sprocket.
  20.  
  21. Apply thread locking compound to the threads of the camshaft sprocket retainer bolts and install to the appropriate shafts. The right bolt is 8.380 in. (21.3cm) long, while the left bolt is 10.0 in. (25.4cm) long. These bolts are not interchangeable. Do not tighten the bolts at this time. The camshaft marks should be positioned between the marks on the cover.
  22.  
  23. Place the crankshaft sprocket to the Top Dead Center (TDC) mark on the oil pump housing. Install the timing belt starting at the crankshaft sprocket and working in a counterclockwise direction.
  24.  
  25. After the belt is installed around the last sprocket keep tension on the belt until it is past the tensioner pulley.
  26.  
  27. Holding the tensioner pulley against the belt, install the tensioner housing and torque to 21 ft. lbs. (28 Nm).
  28.  
  29. When the tensioner is in place pull the retainer pin to allow the tensioner to extend to the pulley bracket.
  30.  
  31. Hold the right camshaft sprocket hex with a 36mm box wrench and torque the right camshaft sprocket bolt to 75 ft. lbs. (102 Nm). Turn the sprocket bolt an additional 90 degrees.
  32.  
  33. Hold the left camshaft sprocket hex with a 36mm box wrench and torque the left camshaft sprocket bolt to 85 ft. lbs. (115 Nm). Turn the sprocket bolt an additional 90 degrees.
  34.  
  35. Install or connect the following:

    Camshaft alignment tools from the back of the cylinder heads
     
    Cam covers and new O-rings. Torque the fasteners to 20 ft. lbs. (27 Nm). Repeat this procedure on the other camshaft.
     
    Timing belt covers and crankshaft damper and torque the crankshaft damper bolt to 85 ft. lbs. (115 Nm)
     
    Valve covers and torque the bolts to 105 inch lbs. (12 Nm)
     
    Spark plug tube nut and O-ring and torque to 60 inch lbs. (7 Nm)
     
    Spark plug and torque to 20 ft. lbs. (28 Nm)
     
    A/C compressor and torque the mounting bracket bolts to 30 ft. lbs. (41 Nm)
     
    Spark plug wires
     
    Accessory drive belts and adjust to the proper tension
     
    Intake manifold plenum using the recommended procedure
     
    Air cleaner assembly
     
    Radiator and cooling fan assemblies
     
    Negative battery cable
     

  36.  
  37. Check to be sure that all hoses, wiring connectors, cables, fluid and vacuum lines are reconnected.
  38.  
  39. Change the engine oil and oil filter.
  40.  
  41. Fill and bleed the cooling system.
  42.  
  43. Run the vehicle with the radiator cap off so coolant can be added as required until the thermostat opens. Watch for leaks and for unusual engine noises. Refill the radiator completely as required.
  44.  
  45. Once the vehicle has cooled, recheck the coolant and oil level.
  46.  

 
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