Avenger 2008

Valve Covers

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Removal & Installation



2.4L Engine
  1. Remove engine cover (1) by pulling upward.

    Click image to see an enlarged view

    Fig. Remove engine cover (1) by pulling upward

  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Remove make up air hose (2).

    Click image to see an enlarged view

    Fig. Remove make up air hose (2)

  6.  
  7. Remove PCV hose (5).
  8.  
  9. Disconnect ignition coil electrical connectors (1).
  10.  
  11. Use compressed air to blow dirt and debris off the cylinder head cover prior to removal.
  12.  
  13. Remove cylinder head cover bolts.

    Click image to see an enlarged view

    Fig. Remove cylinder head cover bolts

  14.  
  15. Remove cylinder head cover from cylinder head.
  16.  

To install:

  1. Install new cylinder head cover gaskets (1,2).

    Click image to see an enlarged view

    Fig. Install new cylinder head cover gaskets (1,2)

  2.  
  3. Install studs in cover.

    Click image to see an enlarged view

    Fig. Install studs in cover

  4.  
  5. Clean all RTV from cylinder head.
    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.

  6.  
  7. Apply a dot of Mopar® engine sealant RTV or equivalent to cylinder head/front cover T-joint (1).

    Click image to see an enlarged view

    Fig. Apply a dot of engine sealant RTV to cylinder head/front cover T-joint (1)

  8.  
  9. Install cylinder head cover assembly to cylinder head and install all bolts, ensuring the studs are located as shown.
  10.  
  11. Tighten bolts in sequence shown using a 2 step torque method as follows:

    Click image to see an enlarged view

    Fig. Install cylinder head cover and tighten in sequence

    1. Tighten all bolts to 44 inch lbs. (5 Nm).
    2.  
    3. Tighten all bolts to 90 inch lbs. (10 Nm).
    4.  

  12.  
  13. Install ignition coils. Tighten fasteners to 70 inch lbs. (8 Nm).
  14.  
  15. If the PCV valve was removed, tighten PCV valve to 44 inch lbs. (5 Nm).
  16.  
  17. Connect coil electrical connectors.
  18.  
  19. Connect PCV hose to PCV valve.
  20.  
  21. Connect make up air hose.
  22.  
  23. Connect negative battery cable.
  24.  
  25. Install engine cover by pressing the rear of the cover down first.
  26.  

2.7L Engine
Left Side

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect negative battery cable.
  2.  
  3. Disconnect electrical connectors from ignition coils and capacitor. Reposition electrical harness.
  4.  
  5. Remove ground strap from cylinder head cover stud.
  6.  
  7. Disconnect engine harness retaining clips (1) from cylinder head cover studs. Position the engine harness (3) aside.

    Click image to see an enlarged view

    Fig. Disconnect engine harness retaining clips (1) from cylinder head cover studs

  8.  
  9. Remove fastener attaching ignition coil capacitor.
  10.  
  11. Remove ignition coils.
  12.  
  13. Loosen all left cylinder head cover fasteners.

    Click image to see an enlarged view

    Fig. Loosen all left cylinder head cover fasteners

  14.  
  15. Disconnect the makeup air hose (4).
    NOTE
    Cylinder head cover attaching bolts are captured to the cover.


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



    Click image to see an enlarged view

    Fig. Disconnect the makeup air hose (4)

  16.  
  17. Remove the left cylinder head cover.
  18.  

To install:

  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 (1).
  4.  
  5. Tighten cylinder head cover attaching bolts and double-ended studs to 105 inch lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Tighten cylinder head cover attaching bolts and double-ended studs

  6.  
  7. Reposition the left engine harness, and install the left engine harness retainers to the double-ended studs.
  8.  
  9. Install the ignition coils.
  10.  
  11. Install ignition coil capacitor and fastener.
  12.  
  13. Reconnect all electrical connectors.
  14.  
  15. Install ground strap to cylinder head cover stud.
  16.  
  17. Install the makeup air hose.
  18.  
  19. Connect negative battery cable.
  20.  

Right Side

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect negative battery cable.
  2.  
  3. Disconnect electrical connectors from ignition coils and capacitor.
  4.  
  5. Disconnect right engine harness retaining clips (2) from cylinder head cover studs. Position the engine harness (6) aside.

    Click image to see an enlarged view

    Fig. Disconnect right engine harness retaining clips (2) from cylinder head cover studs

  6.  
  7. Disconnect the PCV hose from the upper intake manifold.
  8.  
  9. Remove upper intake manifold.
  10.  
  11. Remove ground strap from cylinder head cover stud.
  12.  
  13. Disconnect electrical harness retaining clips from cylinder head cover studs. Reposition electrical harness.
  14.  
  15. Remove fastener attaching ignition coil capacitor.
  16.  
  17. Remove ignition coils.
  18.  
  19. Loosen right cylinder head cover fasteners.
    NOTE
    Cylinder head cover attaching bolts are captured to the cover.


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



    Click image to see an enlarged view

    Fig. Loosen right cylinder head cover fasteners

  20.  
  21. Remove cylinder head cover.
  22.  

To install:

  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 (2) and double-ended studs (1) to 105 inch lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Tighten cylinder head cover attaching bolts (2) and double-ended studs (1)

  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. Reposition the right engine harness, and install the right engine harness retainers to the double-ended studs.
  14.  
  15. Install upper intake manifold.
  16.  
  17. Reconnect the PCV to the upper intake manifold.
  18.  

3.5L Engine
Left Side

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Disconnect and remove the three ignition coils.
  4.  
  5. Disconnect engine harness retaining clips (2) from cylinder head cover studs. Position the engine harness aside.

    Click image to see an enlarged view

    Fig. Disconnect engine harness retaining clips (2) from cylinder head cover studs

  6.  
  7. Disconnect the PCV hose (3) from the valve cover assembly (if required).
  8.  
  9. Completely loosen the eight cylinder head cover retaining bolts (4) and remove the cylinder head cover.
  10.  

To install:

  1. Clean cylinder head and all gasket sealing surfaces. Inspect and replace gasket and seals as necessary.
  2.  
  3. Using a suitable pry tool, carefully remove spark plug tube seals (2).

    Click image to see an enlarged view

    Fig. Using a suitable pry tool, remove spark plug tube seals (2)

  4.  
  5. Position new seal with the part number on seal facing cylinder head cover.
  6.  
  7. Install seals using Camshaft Installer MD-998306 (1).
  8.  
  9. Install cylinder head cover and bolts. Tighten to 90 inch lbs. (10 Nm).
  10.  
  11. Install the PCV hose (if required).
  12.  
  13. Position the wiring harness on the cylinder head cover.
  14.  
  15. Reinstall the wire harness retainers around the perimeter of the valve cover.
  16.  
  17. Install the ignition coils.
  18.  
  19. Connect the ignition coil electrical connectors.
  20.  
  21. Connect negative battery cable.
  22.  

Right Side

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the upper intake manifold from the engine.
  4.  
  5. Cover lower intake manifold intake ports with a clean cover to prevent dirt or debris from entering the ports during service.
  6.  
  7. Disconnect the ignition coil harness connectors (2).

    Click image to see an enlarged view

    Fig. Disconnect the ignition coil harness connectors (2)

  8.  
  9. Remove ignition coils.
  10.  
  11. Disconnect the engine wiring harness retainers from the valve cover.
  12.  
  13. Disconnect the makeup air hose.
  14.  
  15. Completely loosen the cylinder head cover retaining bolts and remove the cylinder head cover.
  16.  

To install:

  1. Clean cylinder head and cover mating surfaces. Inspect and replace gasket and seals as necessary.
  2.  
  3. Using a suitable pry tool, carefully remove spark plug tube seals (2).

    Click image to see an enlarged view

    Fig. Using a suitable pry tool, remove spark plug tube seals (2)

  4.  
  5. Position new seal with the part number on seal facing cylinder head cover.
  6.  
  7. Install seals using Camshaft Installer MD-998306.
  8.  
  9. Install cylinder head cover bolts and tighten to 90 inch lbs. (10 Nm).
  10.  
  11. Reconnect the wire harness retainers to the valve cover.
  12.  
  13. Install the ignition coils.
  14.  
  15. Connect the ignition coil electrical connectors.
  16.  
  17. Reconnect the makeup air hose.
  18.  
  19. Install upper intake manifold.
  20.  
  21. Connect negative battery cable.
  22.  

 
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