Avenger 2008

Cylinder Head 2

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Removal & Installation



2.4L Engine
  1. Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
    NOTE
    Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.


    CAUTION
    Always replace the variable valve timing filter screen (3) when servicing the head gasket or engine damage could result.



    Click image to see an enlarged view

    Fig. Check cylinder head bolts for necking by holding a scale or straight edge against the threads

  2.  
  3. Replace the variable valve timing filter screen (3).
    NOTE
    When using RTV, the sealing surfaces must be clean and free from grease and oil.


    NOTE
    When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.



    Click image to see an enlarged view

    Fig. Replace the variable valve timing filter screen (3)

  4.  
  5. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder block.

    Click image to see an enlarged view

    Fig. Engine sealant RTV or equivalent (1) on cylinder block

  6.  
  7. Position the new cylinder head gasket on engine block with the part number facing up. Ensure gasket is seated over the locating dowels in block.
  8.  
  9. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder head gasket.
    NOTE
    The head must be installed within 15 minutes before the RTV skins.



    Click image to see an enlarged view

    Fig. engine sealant RTV or equivalent (1) on cylinder head gasket

  10.  
  11. Position cylinder head onto engine block.
    CAUTION
    This engine was built with 2 different style cylinder head bolts. Each style bolt requires a different torque value. The bolts can be identified by the short bolt head (1) and the long bolt head (2).



    Click image to see an enlarged view

    Fig. The bolts can be identified by the short bolt head (1) and the long bolt head (2)

  12.  
  13. Measure the bolt head from the washer to the top of the bolt head. The short bolt head (1) measures 5 / 16 inches (8 mm) and the long bolt head (2) measures 1 / 2 inches (13 mm).
  14.  
  15. Identify whether your engine has the short head design (1) or the long head design (2).
    NOTE
    The front two cylinder head bolts do not have captured washers. The washers must be installed with the bevel edge (1) up towards the bolt head.



    Click image to see an enlarged view

    Fig. The washers must be installed with the bevel edge (1) up towards the bolt head

  16.  
  17. Install washers for the front two cylinder head bolts with the beveled edge facing up.
    NOTE
    Before installing the cylinder head bolts, lubricate the threads with clean engine oil.

  18.  
  19. Install the cylinder head bolts and tighten in the sequence shown.

    Click image to see an enlarged view

    Fig. Install the cylinder head bolts and tighten in the sequence shown

  20.  
  21. If your bolt has the short head, use the following torque specifications:
    CAUTION
    Do not use a torque wrench for the Fourth step.



    First: All to 25 ft. lbs. (30 Nm)
     
    Second: All to 45 ft. lbs. (61 Nm)
     
    Third: All to 45 ft. lbs. (61 Nm)
     
    Fourth: All an additional 90°
     

  22.  
  23. If your bolt has the long head, use the following torque specifications:
    CAUTION
    Do not use a torque wrench for the Fourth step.



    First: All to 25 ft. lbs. (30 Nm)
     
    Second: All to 54 ft. lbs. (73 Nm)
     
    Third: All to 54 ft. lbs. (73 Nm)
     
    Fourth: All an additional 90°
     

  24.  
  25. Clean excess RTV from the timing chain cover sealing surface.
  26.  
  27. Install coolant adapter with new seals. Tighten bolts to 159 inch lbs. (18.1 Nm).
  28.  
  29. The front camshaft bearing cap (1) is numbered (2) either one, two, or three, this corresponds to the select fit front exhaust camshaft bearing to use.

    Click image to see an enlarged view

    Fig. The front camshaft bearing cap (1) is numbered (2) either one, two, or three

  30.  
  31. Install the corresponding select fit front exhaust camshaft bearing (1).

    Click image to see an enlarged view

    Fig. Install the corresponding select fit front exhaust camshaft bearing (1)

  32.  
  33. Oil all of the camshaft journals with clean engine oil.
  34.  
  35. Position exhaust camshaft (1) and intake camshaft (2) on bearing journals in the cylinder head.
  36.  
  37. Align camshaft timing marks (3) so that they are facing each other and are in line with the cylinder head cover sealing surface.
    CAUTION
    Install the front intake and exhaust camshaft bearing cap last. Ensure that the dowels are seated and follow torque sequence or damage to engine could result.


    NOTE
    If the front camshaft bearing cap is broken, the cylinder head MUST be replaced.



    Click image to see an enlarged view

    Fig. Align camshaft timing marks (3)

  38.  
  39. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 85 inch lbs. (9.5 Nm) in the sequence shown.
    NOTE
    Verify that the exhaust bearing shells are correctly installed, and the dowels are seated in the head, prior to torquing bolts.



    Click image to see an enlarged view

    Fig. Install intake and exhaust camshaft bearing caps in the sequence shown

  40.  
  41. Install the front intake and exhaust bearing cap and tighten bolts to 18 ft. lbs. (25 Nm) in the sequence shown.

    Click image to see an enlarged view

    Fig. Install the front intake and exhaust bearing cap in the sequence shown

  42.  
  43. Install timing chain guide (4) and tighten bolts to 105 inch lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Install timing chain guide (4)

  44.  
  45. Install the moveable timing chain pivot guide (6) and tighten bolt to 105 inch lbs. (12 Nm).
  46.  
  47. Install timing chain (2) and tensioner (5).
  48.  
  49. Install timing chain cover, engine mount, pulleys and accessory drive belt.
  50.  
  51. Install cylinder head cover and ignition coils.

    Click image to see an enlarged view

    Fig. Install cylinder head cover

  52.  
  53. Install exhaust manifold.
  54.  
  55. Install ground strap at right rear of cylinder head if equipped.
  56.  
  57. Install intake manifold, vacuum lines and fuel rail.
  58.  
  59. Connect coil and injector electrical connectors.
  60.  
  61. Connect electrical connectors to coolant temperature sensor, camshaft position sensors, oil temperature sensor, variable valve timing solenoids, MAP sensor, manifold tuning valve, ignition interference suppressor and electronic throttle control.
  62.  
  63. Install power steering pump reservoir. Tighten mounting screw to 105 inch lbs. (12 Nm).
  64.  
  65. Install coolant recovery reservoir. Tighten mounting bolts to 89 inch lbs. (10 Nm).
  66.  
  67. Install clean air hose and air cleaner housing.
  68.  
  69. Fill cooling system.
  70.  
  71. Install new oil filter and fill engine with oil.
  72.  
  73. Connect negative battery cable.
  74.  
  75. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for leaks and correct fluid levels.
  76.  
  77. Install engine cover.
  78.  

2.7L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Perform fuel pressure release procedure before attempting any repairs.
  2.  
  3. Disconnect negative cable.
  4.  
  5. Drain cooling system.
  6.  
  7. Remove accessory drive belts.
  8.  
  9. Remove the vibration damper.
  10.  
  11. Remove exhaust cross-under pipe.
    WARNING
    The normal operating temperature of the exhaust system is very high. Therefore, never attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation time.



    Click image to see an enlarged view

    Fig. Exhaust system-2.7L engine

    1. Raise vehicle on hoist.
    2.  
    3. Disconnect downstream oxygen sensor connectors.
    4.  
    5. Remove oil pan to transmission structural collar.

      Click image to see an enlarged view

      Fig. Remove oil pan to transmission structural collar

    6.  
    7. Remove three bolts (2) attaching structural collar (3) to oil pan.
    8.  
    9. Remove four bolts (1) and structural collar (3) from transmission.
    10.  
    11. Disconnect exhaust system pipe from cross-under pipe.
    12.  
    13. Remove fasteners attaching cross-under pipe to catalytic converters.
    14.  
    15. Remove cross-under pipe.
    16.  

  12.  
  13. Remove the appropriate catalytic converter.
  14.  
  15. Remove oil pressure sensor heat shield.
  16.  
  17. Disconnect oil pressure sensor connector.
  18.  
  19. Remove upper and lower intake manifolds.
  20.  
  21. Remove cylinder head covers.
  22.  
  23. Disconnect camshaft position sensor and crankshaft position sensor connectors.
  24.  
  25. Reposition engine wiring harness to left side of vehicle.
  26.  
  27. Remove coolant outlet connector (3).

    Click image to see an enlarged view

    Fig. Remove coolant outlet connector (3)

  28.  
  29. Remove timing chain cover.
  30.  
  31. Rotate crankshaft until crankshaft sprocket timing mark aligns with timing mark on oil pump housing.
  32.  
  33. Remove primary timing chain.
  34.  
  35. Remove upper primary timing chain guides.
  36.  
  37. Remove camshaft bearing caps gradually in REVERSE sequence of installation (10-1).

    Click image to see an enlarged view

    Fig. Remove camshaft bearing caps in REVERSE sequence

  38.  
  39. Remove camshafts (10) and valvetrain components from cylinder head. Note component locations for re-installation in original locations.

    Click image to see an enlarged view

    Fig. Exploded view of engine camshaft system components

  40.  
  41. For left cylinder head removal:

    Remove fastener securing engine oil dipstick tube to cylinder head. Remove engine oil dipstick tube.
     
    Remove alternator.
     

  42.  
  43. For right cylinder head removal:
    CAUTION
    Ensure cylinder head bolts 11-9 are removed before attempting the removal of cylinder head, as damage to cylinder head and/or block may occur.



    Remove cylinder head ground strap.
     
    Disconnect EGR valve electrical connector (if equipped).
     

  44.  
  45. Remove cylinder head bolts in reverse sequence of installation starting with bolts 11-9, then bolts 8-1.

    Click image to see an enlarged view

    Fig. Remove cylinder head bolts in reverse sequence of installation

  46.  
  47. Remove cylinder head(s).
  48.  
  49. Remove and discard cylinder head gasket.
  50.  
  51. Clean cylinder head and block sealing surfaces.
  52.  

To install:


NOTE
The cylinder head bolts (4) 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.

Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt must be replaced.

Click image to see an enlarged view

Fig. Check cylinder head bolts for necking by holding a scale or straight edge against the threads


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.
  2.  
  3. Lubricate bolt threads with clean engine oil and install bolts.
  4.  
  5. Install new head gasket over locating dowels.
  6.  
  7. Install cylinder head to block, assuring head is properly positioned over locating dowels.
  8.  
  9. Tighten bolts in sequence shown, using the following steps and torque values:
    NOTE
    Do not use a torque wrench for the above step.



    Click image to see an enlarged view

    Fig. Tighten cylinder head bolts in sequence



    Step 1: Bolts 1-8 to 35 ft. lbs. (48 Nm)
     
    Step 2: Bolts 1-8 to 55 ft. lbs. (75 Nm)
     
    Step 3: Bolts 1-8 to 55 ft. lbs. (75 Nm)
     
    Step 4: Bolts 1-8 to +90° turn
     



    Step 5: Bolts 9-11 to 21 ft. lbs. (28 Nm)
     

  10.  
  11. For left cylinder head installation:

    Install engine oil dipstick tube.
     
    Install alternator.
     

  12.  
  13. For right cylinder head installation:

    Install cylinder head ground strap.
     
    Connect EGR valve electrical connector (if equipped).
     

  14.  
  15. Install all valvetrain components and camshafts. Tighten camshaft bearing caps in sequence shown to 105 inch lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Tighten cam bearing cap bolts in sequence shown

  16.  
  17. Install primary timing chain, guides and sprockets.
  18.  
  19. Install coolant outlet connector.
  20.  
  21. Install cylinder head covers.
  22.  
  23. Connect camshaft position sensor and crankshaft position sensor connectors.
  24.  
  25. Install timing chain cover.
  26.  
  27. Install crankshaft vibration damper.
  28.  
  29. Install lower and upper intake manifolds.
  30.  
  31. Connect oil pressure sensor connector.
  32.  
  33. Install oil pressure sensor heat shield.
  34.  
  35. Install catalytic converter(s).
  36.  
  37. Install exhaust cross-under pipe.
  38.  
  39. Install accessory drive belts.
  40.  
  41. Fill cooling system.
  42.  
  43. Connect negative cable to remote jumper terminal.
  44.  

3.5L Engine
 
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