Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Valve Covers

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Removal & Installation



2.0L & 2.4L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Remove or disconnect the following:

    Ignition coil pack
     
    Cylinder head cover bolts
     
    Cylinder head cover from cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head cover bolt tightening sequence-2.0L and 2.4L engines

     

  6.  

To install:


WARNING
Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping.


NOTE
Clean cylinder head and cover mating surfaces and make sure they are flat.

  1. Install or connect the following:
    NOTE
    After tightening the bolts, re-torque to 200 inch lbs. (23 Nm) in a crisscross pattern.



    Cover assembly to head with a new gasket and torque the bolts to 105 inch lbs. (12 Nm)
     
    Ignition coil pack and torque the bolts to 200 inch lbs. (23 Nm) in a crisscross pattern.
     



    Battery cable.
     

  2.  

Spark Plug Tube Seals

The spark plug tube seals are located on the end of each tube. These seals slide onto each tube to seal the cylinder head cover to spark plug tube. If these seals show signs of hardness and/or cracks, they should be replaced.

Click image to see an enlarged view

Fig. Location of spark plug well seals-2.0L and 2.4L engines

2.4L Engine
  1. Remove the ignition coil and plug wires.
  2.  
  3. Remove the ground strap.
  4.  
  5. Remove the cylinder head cover fasteners.
  6.  
  7. Remove the cylinder head cover from cylinder head.
  8.  

To install:

  1. Install the new cylinder head cover gaskets and spark plug seals.
    WARNING
    Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping.

  2.  
  3. Apply MOPAR® Engine RTV GEN II, or equivalent, at the camshaft cap corners and at the top edge of the half-round seal.
  4.  
  5. Install the cylinder head cover to head and tighten fasteners in sequence shown using the 3 step torque method:
    1. Tighten all fasteners to 40 inch lbs. (4.5 Nm)
    2.  
    3. Tighten all fasteners to 80 inch lbs. (9.0 Nm)
    4.  
    5. Tighten all fasteners to 105 inch lbs. (12 Nm)
    6.  

  6.  
  7. Install the ignition coil and plug wires.
    1. Tighten ignition coil fasteners to 105 inch lbs. (12 Nm)
    2.  

  8.  
  9. Install the ground strap.

    Click image to see an enlarged view

    Fig. Cylinder head cover tightening sequence

  10.  

2.5L Engines
Front Cylinder Head Cover
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Disconnect and relocate spark plug cables and wiring harness.
  6.  
  7. Disconnect PCV and breather hoses.
  8.  
  9. Remove cylinder head cover fasteners and remove cover.
  10.  

To install:

  1. Clean cylinder head and cover mating surfaces. Install new gasket.
  2.  
  3. Install cover and tighten cover bolt washer and gasket assembly to 88 inch lbs. (10 Nm)
  4.  
  5. Connect PCV and breather hoses.
  6.  
  7. Connect spark plug cables and wiring harness.
  8.  

  1. Disconnect and relocate spark plug cables and wiring harness.
  2.  
  3. Disconnect PCV and breather hoses.
  4.  
  5. Remove the cylinder head cover fasteners and remove cover
  6.  

To install:

  1. Make certain the cylinder head cover rails are flat.
  2.  
  3. Clean cylinder head and cover mating surfaces. Install the new gasket.
  4.  
  5. Install the cover and tighten cover bolt washer and gasket assembly to 88 inch lbs. (10 Nm)
  6.  
  7. Connect PCV and breather hoses.
  8.  
  9. Connect spark plug cables and wiring harness.
    NOTE
    The spark plug tube seals are located on the end of each tube. These seals slide onto each tube to seal the cylinder head cover to spark plug tube. Replace seals if hardened or cracked.

  10.  

Rear Cylinder Head Cover
  1. Remove upper intake manifold. Refer to procedure in intake manifold section.
    NOTE
    Cover lower intake manifold with a suitable cover during service.

  2.  
  3. Disconnect and relocate spark plug cables.
  4.  
  5. Disconnect breather hose.
  6.  
  7. Remove cylinder head cover fasteners and remove cover.
  8.  

To install:

  1. Clean cylinder head and cover mating surfaces. Install new gasket.
  2.  
  3. Install cover and tighten cover bolt washer and gasket assembly to 88 inch lbs. (10 Nm)
  4.  
  5. Connect spark plug cables.
  6.  
  7. Connect breather hose.
  8.  
  9. Install upper intake manifold. Refer to intake manifold section.
  10.  

  1. Remove the upper intake manifold. Refer to procedure in this section.
  2.  
  3. Cover lower intake manifold with a suitable cover during service.
  4.  
  5. Disconnect and relocate spark plug cables.
  6.  
  7. Disconnect breather hose.
  8.  
  9. Remove the cylinder head cover fasteners and remove cover
  10.  

To install:

  1. Make certain the cylinder head cover rails are flat.
  2.  
  3. Clean cylinder head and cover mating surfaces. Install the new gasket.
  4.  
  5. Install the cover and tighten cover bolt washer and gasket assembly to 88 inch lbs. (10 Nm)
  6.  
  7. Connect spark plug cables.
  8.  
  9. Connect breather hose.
  10.  
  11. Install the upper intake manifold.
    NOTE
    The spark plug tube seals are located on the end of each tube. These seals slide onto each tube to seal the cylinder head cover to spark plug tube. Replace seals if hardened or cracked.

  12.  

Spark Plug Tube Seal

The spark plug tube seals are located on the end of each tube. These seals slide onto each tube to seal the cylinder head cover to spark plug tube. If these seals show signs of hardness and/or cracks, they should be replaced.

Click image to see an enlarged view

Fig. Location of spark plug well seals-2.5L and 3.0L engines

2.7L Engine
  1. Disconnect negative battery cable.
  2.  
  3. Remove the upper intake manifold.
  4.  
  5. Disconnect the electrical connectors from ignition coils and capacitor. Reposition electrical harness.
  6.  
  7. Remove the make up air hose from cylinder head cover grommet (right side cover only).
  8.  
  9. Remove the ground strap from cylinder head cover stud.
  10.  
  11. Disconnect electrical harness retaining clips from cylinder head cover studs. Reposition electrical harness.
  12.  
  13. Remove the fastener attaching ignition coil capacitor.
  14.  
  15. Remove the ignition coils.
  16.  
  17. Loosen all cylinder head cover fasteners.
    1. Cylinder head cover attaching bolts are captured to the cover.
    2.  
    3. Make certain the double ended studs in the center of the cylinder head cover are loose before attempting to remove cover.
    4.  
    5. Note the locations of double ended studs for reinstallation.
    6.  

  18.  
  19. Remove the cylinder head cover.
  20.  

To install:

  1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gaskets as necessary.
  2.  
  3. Install the cylinder head cover and hand start all fasteners.
    1. Verify that all double-ended studs are in the correct locations as previously noted.
    2.  

  4.  
  5. Tighten cylinder head cover attaching bolts and double-ended studs to: 105 inch lbs. (12 Nm).
  6.  
  7. Install the ignition coils.
  8.  
  9. Install the ignition coil capacitor and fastener.
  10.  
  11. Connect make up air hose (right side cover only).
  12.  
  13. Connect all electrical connectors and harness clips.
  14.  
  15. Install the ground strap to cylinder head cover stud.
  16.  
  17. Install the upper intake manifold.
  18.  
  19. Connect negative battery cable.
  20.  

3.0L Engine
Front Cylinder Head Cover
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Disconnect and relocate spark plug cables and wiring harness.
  6.  
  7. Disconnect PCV and breather hoses.
  8.  
  9. Remove cylinder head cover fasteners and remove cover.
  10.  

To install:

  1. Clean cylinder head and cover mating surfaces. Install new gasket.
  2.  
  3. Install cover and tighten cover bolt washer and gasket assembly to 31 inch lbs. (3.4 Nm)
  4.  
  5. Connect PCV and breather hoses.
  6.  
  7. Connect spark plug cables and wiring harness.
  8.  

Rear Cylinder Head Cover
  1. Remove upper intake manifold. Refer to procedure in intake manifold section.
    NOTE
    Cover lower intake manifold with a suitable cover during service.

  2.  
  3. Disconnect and relocate spark plug cables.
  4.  
  5. Disconnect breather hose.
  6.  
  7. Remove cylinder head cover fasteners and remove cover.
  8.  

To install:

  1. Clean cylinder head and cover mating surfaces. Install new gasket.
  2.  
  3. Install cover and tighten cover bolt washer and gasket assembly to 31 inch lbs. (3.4 Nm)
  4.  
  5. Connect spark plug cables.
  6.  
  7. Connect breather hose.
  8.  
  9. Install upper intake manifold. Refer to intake manifold section.
  10.  

Spark Plug Tube Seals

The spark plug tube seals are located on the end of each tube. These seals slide onto each tube to seal the cylinder head cover to spark plug tube. If these seals show signs of hardness and/or cracks, they should be replaced.

Click image to see an enlarged view

Fig. Location of spark plug well seals-2.5L and 3.0L engines

 
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