Cherokee, Grand Cherokee, 1999-2005

Cylinder Head

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Removal & Installation



2.5L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Keep valve train components in order for reassembly.



    Negative battery cable
     
    Crankcase Ventilation (CCV) hoses
     
    Air cleaner assembly
     
    Valve cover
     



    Rocker arms
     
    Pushrods
     
    Accessory drive belt
     
    A/C compressor and bracket, if equipped
     
    Power steering pump and bracket, if equipped
     
    Fuel line
     
    Combination manifold
     
    Thermostat housing coolant hoses
     
    Spark plugs
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Cylinder head
     

  8.  

To install:

Click image to see an enlarged view

Fig. Alignment dowel locations-2.5L engine



Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L engine


WARNING
Cylinder head bolts may only be reused one time. If reusing a cylinder head bolt, place a paint mark on the bolt after installation. If a cylinder head bolt has a paint mark, discard it and use a new bolt.

  1. Fabricate two alignment dowels from old cylinder head bolts. Cut the hex head off of the bolts, and cut a slot in each dowel to ease removal.
  2.  
  3. Install or connect the following:

    One dowel in bolt hole No. 8, and one dowel in bolt hole No. 10.
     
    Cylinder head and gasket.
     
    Cylinder head bolts except for No 8 and No 10. Coat the threads of bolt No. 7 with Loctite® 592 sealant.
     

  4.  
  5. Remove the alignment dowels and install the No. 8 and No. 10 head bolts.
    WARNING
    During the final tightening sequence, bolt No. 7 will be tightened to a lower torque value than the rest of the bolts. Do not over tighten bolt No. 7.

  6.  
  7. Tighten the cylinder head bolts, in sequence, as follows:
    1. Step 1: 22 ft. lbs. (30 Nm)
    2.  
    3. Step 2: 45 ft. lbs. (61 Nm)
    4.  
    5. Step 3: 45 ft. lbs. (61 Nm)
    6.  
    7. Step 4: Bolts 1-6 to 110 ft. lbs. (149 Nm)
    8.  
    9. Step 5: Bolt 7 to 100 ft. lbs. (136 Nm)
    10.  
    11. Step 6: Bolts 8-10 to 110 ft. lbs. (149 Nm)
    12.  
    13. Step 7: Repeat steps 4, 5 and 6
    14.  

  8.  
  9. Install or connect the following:

    ECT sensor connector
     
    Spark plugs
     
    Thermostat housing coolant hoses
     
    Combination manifold
     
    Fuel line
     
    Power steering pump and bracket, if equipped
     
    A/C compressor and bracket, if equipped
     
    Accessory drive belt
     
    Pushrods and rocker arms in their original positions
     
    Valve cover
     
    Air cleaner assembly
     
    CCV hoses
     
    Negative battery cable
     

  10.  
  11. Fill and bleed the cooling system.
  12.  
  13. Start the engine, check for leaks and repair if necessary.
  14.  

3.7L Engine
Left Side
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the negative cable from the battery.
  4.  
  5. Raise the vehicle on a hoist.
  6.  
  7. Disconnect the exhaust pipe at the left side exhaust manifold.
  8.  
  9. Drain the engine coolant.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the intake manifold.
  14.  
  15. Siphon the master cylinder.
  16.  
  17. Remove the primary brake line at the master cylinder.
  18.  
  19. Remove the primary brake line from the HCU.
  20.  
  21. Remove the secondary brake line at the master cylinder.
  22.  
  23. Remove the secondary brake line at the HCU.
  24.  
  25. Remove the 4 chassis lines at the HCU.
  26.  
  27. Disconnect the HCU electrical connector.
  28.  
  29. Remove the 3 mounting nuts at the HCU bracket.
  30.  
  31. Remove the HCU with the bracket from the vehicle.
  32.  
  33. Disconnect the brake fluid level sensor electrical connector from the fluid reservoir.
  34.  
  35. Remove the 2 master cylinder mounting nuts.
  36.  
  37. Remove the master cylinder.
  38.  
  39. Disconnect vacuum hose at booster check valve.
  40.  
  41. Remove the hush panel.
  42.  
  43. Remove the steering column opening cover and hush panel.
  44.  
  45. Remove retainer clip that holds booster push rod on pedal pin. Then slide push rod off pin.
  46.  
  47. Disconnect the brake lamp switch wire connector.
  48.  
  49. Remove the brake lamp switch.
  50.  
  51. Remove four nuts that attach booster to dash panel.
  52.  
  53. In the engine compartment, disconnect the wire harness routing clips and move the harness to the side and downward.
  54.  
  55. Remove the booster from the vehicle.
  56.  
  57. Remove the cylinder head cover
  58.  
  59. Remove the fan shroud and fan blade assembly
  60.  
  61. Remove accessory drive belt.
  62.  
  63. Remove the power steering pump and set aside.
  64.  
  65. Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark.
  66.  
  67. Verify the V6 mark on the camshaft sprocket is at the 12 o-clock position, with the No. 1 cylinder at TDC on the exhaust stroke. Rotate the crankshaft one turn if necessary.
  68.  
  69. Remove the crankshaft damper.
  70.  
  71. Remove the timing chain cover.
  72.  
  73. Lock the secondary timing chains to the idler sprocket using Special Tool 8429 Timing Chain Holding Fixture.
    NOTE
    Mark the secondary timing chain prior to removal to aid in installation.

  74.  
  75. Mark the secondary timing chain, one link on each side of the V6 mark on the camshaft drive gear.
  76.  
  77. Remove the left side secondary chain tensioner.
  78.  
  79. Remove the cylinder head access plug.
  80.  
  81. Remove the left side secondary chain guide.
  82.  
  83. Remove the retaining bolt and the camshaft drive gear.
    WARNING
    Do not allow the engine to rotate. Severe damage to the valve train can occur.


    NOTE
    Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts.


    NOTE
    The cylinder head is attached to the cylinder block with twelve bolts.

  84.  
  85. Remove the cylinder head retaining bolts.
  86.  
  87. Remove the cylinder head and gasket. Discard the gasket.
    WARNING
    Do not lay the cylinder head on its gasket sealing surface, due to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from properly sealing resulting in leaks.

  88.  

To install:


NOTE
The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined before reuse. If the threads are necked down the bolts should 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 should be replaced.


WARNING
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 the cylinder head and cylinder block mating surfaces.
  2.  
  3. Position the new cylinder head gasket on the locating dowels.
    WARNING
    When installing cylinder head, use care not damage the tensioner arm or the guide arm.

  4.  
  5. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
    NOTE
    The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.

  6.  
  7. Lubricate the cylinder head bolt threads with clean engine oil and install the eight M11 bolts.
  8.  
  9. Coat the four M8 cylinder head bolts with Mopar® Lock and Seal Adhesive, or equivalent, then install the bolts.
    NOTE
    The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.

  10.  
  11. Tighten the bolts in sequence using the following steps and torque values:

    Step 1: Tighten bolts 1-8 to 20 ft. lbs.(27 Nm).
     
    Step 2: Verify that bolts 1-8, all reached 20 ft. lbs.(27 Nm), by repeating step 1 without loosening the bolts.
     
    Step 3: Tighten bolts 9-12 to 10 ft. lbs. (14 Nm).
     
    Step 4: Tighten bolts 1-8, 90 degrees.
     
    Step 5: Tighten bolts 1-8, 90 degrees, again.
     
    Step 6: Tighten bolts 9-12 to 19 ft. lbs. (26 Nm).
     

  12.  
  13. Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V6 mark on the gear then using Special Tool 8428 Camshaft Wrench, position the gear onto the camshaft.
    WARNING
    Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Failure to do so may cause over-torquing of bolt resulting in bolt failure.

  14.  
  15. Install the camshaft drive gear retaining bolt.
  16.  
  17. Install the left side secondary chain guide.
  18.  
  19. Install the cylinder head access plug.
  20.  
  21. Re-set and install the left side secondary chain tensioner.
  22.  
  23. Install the timing chain cover.
  24.  
  25. Install the crankshaft damper. Tighten damper bolt 130 ft. lbs. (175 Nm).
  26.  
  27. Install the power steering pump.
  28.  
  29. Install the fan blade assembly and fan shroud.
  30.  
  31. Install the cylinder head cover.
  32.  
  33. Check condition of grommet that secures check valve in booster. Replace grommet if cut, torn, or loose.
  34.  
  35. Install new booster dash seal.
  36.  
  37. Align and position booster in the mounting holes of the dash panel.
  38.  
  39. Inside the vehicle, Lubricate pedal pin Mopar® multi-mileage grease.
  40.  
  41. Install booster attaching nuts on studs. Tighten attaching nuts to 29 ft. lbs. (39Nm).
  42.  
  43. Slide booster push rod on pedal pin. Then secure rod to pin with retainer clip.
  44.  
  45. Install a new brake lamp switch and reconnect the electrical connector.
  46.  
  47. Install the steering column opening cover.
  48.  
  49. Install the hush panel.
  50.  
  51. In engine compartment, attach vacuum hose to booster check valve.
  52.  
  53. Install the master cylinder to the power brake booster with new gasket and nuts.
  54.  
  55. Reroute the wire harness back into position and install the routing clip.
  56.  
  57. Reconnect the brake fluid level electrical connector.
  58.  
  59. Install the HCU with bracket to the vehicle and tighten the 2 mounting nuts.
  60.  
  61. Reconnect the HCU electrical connector.
  62.  
  63. Install the 4 chassis lines at the HCU.
  64.  
  65. Install the secondary brake line at the HCU.
  66.  
  67. Install the secondary brake line at the master cylinder.
  68.  
  69. Install the primary brake line at the HCU.
  70.  
  71. Install the primary brake line at the master cylinder.
  72.  
  73. Fill and bleed brake system.
  74.  
  75. Install the intake manifold.
  76.  
  77. Refill the cooling system.
  78.  
  79. Raise the vehicle.
  80.  
  81. Install the exhaust pipe onto the left exhaust manifold.
  82.  
  83. Lower the vehicle.
  84.  
  85. Connect the negative cable to the battery.
  86.  
  87. Start the engine and check for leaks.
  88.  

Right Side
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect battery negative cable.
  4.  
  5. Raise the vehicle on a hoist.
  6.  
  7. Disconnect the exhaust pipe at the right side exhaust manifold.
  8.  
  9. Drain the engine coolant.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the intake manifold.
  14.  
  15. Remove the cylinder head cover.
  16.  
  17. Remove the fan shroud.
  18.  
  19. Remove oil fill housing from cylinder head.
  20.  
  21. Remove accessory drive belt.
  22.  
  23. Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark.
  24.  
  25. Verify the V6 mark on the camshaft sprocket is at the 12 o-clock position. Rotate the crankshaft one turn if necessary.
  26.  
  27. Remove the crankshaft damper.
  28.  
  29. Remove the timing chain cover.
  30.  
  31. Lock the secondary timing chains to the idler sprocket using Special Tool 8429 Timing Chain Holding Fixture.
    NOTE
    Mark the secondary timing chain prior to removal to aid in installation.

  32.  
  33. Mark the secondary timing chain, one link on each side of the V6 mark on the camshaft drive gear.
  34.  
  35. Remove the right side secondary chain tensioner.
  36.  
  37. Remove the cylinder head access plug.
  38.  
  39. Remove the right side secondary chain guide.
    WARNING
    The nut on the right side camshaft sprocket should not be removed for any reason, as the sprocket and camshaft sensor target wheel is serviced as an assembly. If the nut was removed, torque nut to 44 inch lbs. (5 Nm).

  40.  
  41. Remove the retaining bolt and the camshaft drive gear.
    WARNING
    Do not allow the engine to rotate. Severe damage to the valve train can occur.


    NOTE
    Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts.


    WARNING
    Do not hold or pry on the camshaft target wheel for any reason. A damaged target wheel can result in a vehicle no start condition.


    NOTE
    The cylinder head is attached to the cylinder block with twelve bolts.

  42.  
  43. Remove the cylinder head retaining bolts.
  44.  
  45. Remove the cylinder head and gasket. Discard the gasket.
    WARNING
    Do not lay the cylinder head on its gasket sealing surface, do to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from properly sealing resulting in leaks.

  46.  

To install:


NOTE
The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined before reuse. If the threads are necked down the bolts should 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 should be replaced.


WARNING
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 the cylinder head and cylinder block mating surfaces.
  2.  
  3. Position the new cylinder head gasket on the locating dowels.
    WARNING
    When installing cylinder head, use care not damage the tensioner arm or the guide arm.

  4.  
  5. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
    NOTE
    The four M8 cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.

  6.  
  7. Lubricate the cylinder head bolt threads with clean engine oil and install the eight M10 bolts.
  8.  
  9. Coat the four M8 cylinder head bolts with Mopar® Lock and Seal Adhesive, or equivalent, then install the bolts.
    NOTE
    The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.

  10.  
  11. Tighten the bolts in sequence using the following steps and torque values:
    WARNING
    The nut on the right side camshaft sprocket should not be removed for any reason, as the sprocket and camshaft sensor target wheel is serviced as an assembly. If the nut was removed, torque nut to 60 inch lbs. (5 Nm).



    Step 1: Tighten bolts 1-8, to 20 ft. lbs. (27 Nm).
     
    Step 2: Verify that bolts 1-8, all reached 20 ft. lbs. (27 Nm), by repeating step 1 without loosening the bolts.
     
    Step 3: Tighten bolts 9 through 12 to 10 ft. lbs. (14 Nm).
     
    Step 4: Tighten bolts 1-8, 90°.
     
    Step 5: Tighten bolts 1-8, 90°, again.
     
    Step 6: Tighten bolts 9-12, to 19 ft. lbs. (26 Nm)
     

  12.  
  13. Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V6 mark on the gear then using Special Tool 8428 Camshaft Wrench, position the gear onto the camshaft.
    WARNING
    Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Failure to do so may cause over-torquing of bolt resulting in bolt failure.

  14.  
  15. Install the camshaft drive gear retaining bolt.
  16.  
  17. Install the right side secondary chain guide.
  18.  
  19. Install the cylinder head access plug.
  20.  
  21. Re-set and install the right side secondary chain tensioner.
  22.  
  23. Remove Special Tool 8429.
  24.  
  25. Install the timing chain cover.
  26.  
  27. Install the crankshaft damper. Tighten damper bolt 130 ft. lbs. (175 Nm).
  28.  
  29. Install accessory drive belt.
  30.  
  31. Install the fan shroud.
  32.  
  33. Install the cylinder head cover.
  34.  
  35. Install the intake manifold.
  36.  
  37. Install oil fill housing onto cylinder head.
  38.  
  39. Refill the cooling system.
  40.  
  41. Raise the vehicle.
  42.  
  43. Install the exhaust pipe onto the right exhaust manifold.
  44.  
  45. Lower the vehicle.
  46.  
  47. Reconnect battery negative cable.
  48.  
  49. Start the engine and check for leaks.
  50.  

4.0L Engine

NOTE
This procedure can be done with the engine in or out of the vehicle. Disconnect the battery negative cable.


WARNING
Do not remove the cylinder block drain plugs or loosen the radiator drain cock with the system hot and pressurized because serious burns from the coolant can occur.

  1. Drain the coolant and disconnect the hoses at the engine thermostat housing and the water pump inlet. DO NOT waste reusable coolant. If the solution is clean and is being drained only to service the engine or cooling system, drain the coolant into a clean container for reuse.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the cylinder head cover.
  6.  
  7. Remove the cap screws, bridge and pivot assemblies and rocker arms.
  8.  
  9. Remove the push rods. Retain the push rods, bridges, pivots and rocker arms in the same order as removed.
  10.  
  11. Remove the accessory drive belt.
  12.  
  13. Remove the A/C compressor mounting bolts and secure the compressor to the side.
  14.  
  15. Remove the power steering pump and bracket from the intake manifold and water pump. Set the pump and bracket aside. DO NOT disconnect the hoses.
  16.  
  17. Perform the Fuel System Pressure Release procedure.
  18.  
  19. Disconnect the fuel supply line at the fuel rail.
  20.  
  21. Remove the intake and exhaust manifolds from the engine cylinder head.
  22.  
  23. Remove the coil rail.
  24.  
  25. Remove spark plugs.
  26.  
  27. Disconnect the temperature sending unit wire connector.
  28.  
  29. Remove the engine cylinder head bolts. Bolt No.14 cannot be removed until the head is moved forward. Pull bolt No.14 out as far as it will go and then suspend the bolt in this position (tape around the bolt).
  30.  
  31. Remove the engine cylinder head and gasket.
  32.  
  33. If this was the first time the bolts were removed, put a paint dab on the top of the bolt. If the bolts have a paint dab on the top of the bolt or it isn't known if they were used before, discard the bolts.
  34.  
  35. Stuff a clean lint free shop towels into the cylinder bores.
  36.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence for the 4.0L engine


NOTE
This procedure can be done with the engine in or out of the vehicle. The engine cylinder head gasket is a composition gasket. The gasket is to be installed DRY. DO NOT use a gasket sealing compound on the gasket.


NOTE
If the engine cylinder head is to be replaced and the original valves used, measure the valve stem diameter. Only standard size valves can be used with a service replacement engine cylinder head unless the replacement head valve stem guide bores are reamed to accommodate oversize valve stems. Remove all carbon buildup and reface the valves.

  1. Remove the shop towels from the cylinder bores. Coat the bores with clean engine oil. Position the engine cylinder head gasket (with the numbers facing up) using the alignment dowels in the cylinder block, to position the gasket.
    CAUTION
    Engine cylinder head bolts should be reused only once. Replace the head bolts if they were used before or if they have a paint dab on the top of the bolt.

  2.  
  3. With bolt No.14 held in place (tape around bolt), install the engine cylinder head over the same dowels used to locate the gasket. Remove the tape from bolt No.14.
  4.  
  5. Coat the threads of stud bolt No.11 with Loctite 592 sealant, or equivalent.
  6.  
  7. Tighten the engine cylinder head bolts in sequence according to the following procedure
    CAUTION
    During the final tightening sequence, bolt No.11 will be tightened to a lower torque than the rest of the bolts. DO NOT over tighten bolt No.11.

  8.  
  9. Tighten all bolts in sequence (1 through 14) to 22 ft. lbs. (30 Nm).
  10.  
  11. Tighten all bolts in sequence (1 through 14) to 45 ft. lbs. (61 Nm).
  12.  
  13. Check all bolts to verify they are set to 45 ft. lbs. (61 Nm).
  14.  
  15. Tighten bolts in sequence:
  16.  
  17. Bolts 1 through 10 to 110 ft. lbs. (149 Nm).
  18.  
  19. Bolt 11 to 100 ft. lbs. (135 Nm).
  20.  
  21. Bolts 12 through 14 to 110 ft. lbs. (149 Nm).
  22.  
  23. Check all bolts in sequence to verify the correct torque.
  24.  
  25. If not already done, clean and mark each bolt with a dab of paint after tightening. Should you encounter bolts which were painted in an earlier service operation, replace them.
  26.  
  27. Install the spark plugs.
  28.  
  29. Connect the temperature sending unit wire connector.
  30.  
  31. Install the ignition coil rail.
  32.  
  33. Install the intake and exhaust manifolds.
  34.  
  35. Install the fuel line.
  36.  
  37. Attach the power steering pump and bracket.
  38.  
  39. Install the push rods, rocker arms, pivots and bridges in the order they were removed.
  40.  
  41. Install the engine cylinder head cover.
  42.  
  43. Attach the air conditioner compressor mounting bracket to the engine cylinder head and block. Tighten the bolts to 30 ft. lbs. (40 Nm).
  44.  
  45. Attach the air conditioning compressor to the bracket. Tighten the bolts to 20 ft. lbs. (27 Nm).
    CAUTION
    The serpentine drive belt must be routed correctly. Incorrect routing can cause the water pump to turn in the opposite direction causing the engine to overheat.

  46.  
  47. Install the serpentine drive belt.
  48.  
  49. Install the air cleaner and ducting.
  50.  
  51. Connect the hoses to the engine thermostat housing and fill the cooling system to the specified level.
  52.  
  53. The automatic transmission throttle linkage and cable must be adjusted after completing the engine cylinder head installation.
  54.  
  55. Install the temperature sending unit and connect the wire connector.
  56.  
  57. If equipped with air conditioning, install A/C compressor and charge A/C system.
  58.  
  59. Connect negative cable to battery.
    WARNING
    Use extreme caution when the engine is operating. Do not stand in direct line with the fan. Do not put hands near the pulleys, belts or fan. Do not wear loose clothing.

  60.  
  61. Operate the engine with the radiator cap off. Inspect for leaks and continue operating the engine until the engine thermostat opens. Add coolant, if required.
  62.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Keep valve train components in order for reassembly.



    Negative battery cable
     
    Crankcase Ventilation (CCV) hoses
     
    Air cleaner assembly
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Control cable bracket
     
    Valve cover
     



    Rocker arms
     
    Pushrods
     
    Accessory drive belt
     
    A/C compressor and bracket, if equipped
     
    Power steering pump and bracket, if equipped
     
    Fuel line
     
    Combination manifold
     
    Thermostat housing coolant hoses
     
    Spark plugs
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Cylinder head
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-4.0L engine


WARNING
Cylinder head bolts may only be reused one time. If reusing a cylinder head bolt, place a paint mark on the bolt after installation. If a cylinder head bolt has a paint mark, discard it and use a new bolt.

  1. Install the cylinder head with a new gasket. Coat the threads of bolt No. 11 with Loctite®F 592 sealant.
    CAUTION
    During the final tightening sequence, bolt No. 11 will be tightened to a lower torque value than the rest of the bolts. Do not over tighten bolt No. 11.

  2.  
  3. Tighten the cylinder head bolts, in sequence, as follows:
    1. Step 1: 22 ft. lbs. (30 Nm)
    2.  
    3. Step 2: 45 ft. lbs. (61 Nm)
    4.  
    5. Step 3: 45 ft. lbs. (61 Nm)
    6.  
    7. Step 4: Bolts 1-10 to 110 ft. lbs. (149 Nm)
    8.  
    9. Step 5: Bolt 11 to 100 ft. lbs. (136 Nm)
    10.  
    11. Step 6: Bolts 12-14 to 110 ft. lbs. (149 Nm)
    12.  
    13. Step 7: Repeat steps 4, 5 and 6
    14.  

  4.  
  5. Install or connect the following:

    ECT sensor connector
     
    Spark plugs
     
    Thermostat housing coolant hoses
     
    Combination manifold
     
    Fuel line
     
    Power steering pump and bracket, if equipped
     
    A/C compressor and bracket, if equipped. Torque the bolts to 30 ft. lbs. (40 Nm).
     
    Accessory drive belt
     
    Pushrods and rocker arms in their original positions
     
    Valve cover
     
    Control cable bracket
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator cable
     
    Air cleaner assembly
     
    CCV hoses
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

4.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust Y-pipe
     
    Intake manifold
     
    Valve covers
     
    Engine cooling fan and shroud
     
    Accessory drive belt
     
    Oil fill housing
     
    Power steering pump
     
    Rocker arms
     

  8.  
  9. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V8 marks on the camshaft sprockets are at 12 o-clock as shown.

    Click image to see an enlarged view

    Fig. Crankshaft timing marks-4.7L engine



    Click image to see an enlarged view

    Fig. Camshaft positioning-4.7L engine

  10.  
  11. Remove or disconnect the following:

    Crankshaft damper
     
    Front cover

    Click image to see an enlarged view

    Fig. Cylinder head access plug locations-4.7L engine



    Click image to see an enlarged view

    Fig. Use the special tool to lock the timing chains on the idler gear-4.7L engine

     

  12.  
  13. Lock the secondary timing chains to the idler sprocket with Timing Chain Locking tool 8515.
  14.  
  15. Matchmark the secondary timing chains to the camshaft sprockets.
  16.  
  17. Remove or disconnect the following:
    NOTE
    Each cylinder head is retained by ten 11mm bolts and four 8mm bolts.



    Secondary timing chain tensioners
     
    Cylinder head access plugs
     
    Secondary timing chain guides
     
    Camshaft sprockets
     
    Cylinder heads
     

  18.  

To install:

Click image to see an enlarged view

Fig. Examine the head bolts for signs of stretching-4.7L engine



Click image to see an enlarged view

Fig. Cylinder head torque sequence-4.7L engine

  1. Check the cylinder head bolts for signs of stretching and replace as necessary.
  2.  
  3. Lubricate the threads of the 11mm bolts with clean engine oil.
  4.  
  5. Coat the threads of the 8mm bolts with Mopar® Lock and Seal Adhesive.
  6.  
  7. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows:
    1. Step 1: Bolts 1-10 to 15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: Bolts 1-10 to 35 ft. lbs. (47 Nm)
    4.  
    5. Step 3: Bolts 11-14 to 18 ft. lbs. (25 Nm)
    6.  
    7. Step 4: Bolts 1-10 plus 1 / 4 (90 degree) turn
    8.  
    9. Step 5: Bolts 11-14 to 19 ft. lbs. (26 Nm)
    10.  

  8.  
  9. Install or connect the following:

    Camshaft sprockets. Align the secondary chain matchmarks and tighten the bolts to 90 ft. lbs. (122 Nm).
     
    Secondary timing chain guides
     
    Cylinder head access plugs
     
    Secondary timing chain tensioners.
     

  10.  
  11. Remove the Timing Chain Locking tool 8515.
  12.  
  13. Install or connect the following:

    Front cover
     
    Crankshaft damper. Torque the bolt to 130 ft. lbs. (175 Nm).
     
    Rocker arms
     
    Power steering pump
     
    Oil fill housing
     
    Accessory drive belt
     
    Engine cooling fan and shroud
     
    Valve covers
     
    Intake manifold
     
    Exhaust Y-pipe
     
    Negative battery cable
     

  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Start the engine, check for leaks and repair if necessary.
  18.  

5.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Perform the Fuel System Pressure Release procedure. Disconnect the fuel supply line.
  4.  
  5. Disconnect the battery negative cable.
  6.  
  7. Drain cooling system.
  8.  
  9. Remove the air cleaner resonator and duct work.
  10.  
  11. Remove closed crankcase ventilation system.
  12.  
  13. Disconnect the exhaust at the exhaust manifolds.
  14.  
  15. Disconnect the evaporation control system.
  16.  
  17. Disconnect heater hoses.
  18.  
  19. Remove the power steering pump.

    Click image to see an enlarged view

    Fig. Cylinder head cover bolt removal and tightening sequence-5.7L engine

  20.  
  21. Remove cylinder head covers, using the sequence provided, and gaskets.
  22.  
  23. Remove intake manifold and throttle body as an assembly.
  24.  
  25. Remove rocker arm assemblies and push rods. Identify to ensure installation in original locations.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal and tightening sequence-5.7L engine

  26.  
  27. Remove the head bolts from each cylinder head, using the sequence provided, and remove cylinder heads. Discard the cylinder head gasket.
  28.  

To install:

  1. Clean all surfaces of cylinder block and cylinder heads.
  2.  
  3. Clean cylinder block front and rear gasket surfaces using a suitable solvent.
    NOTE
    The head gaskets are not interchangeable between left and right sides. They are marked -L- and -R- to indicate left and right sides. The head gaskets are also marked -TOP- to indicate which side goes up.

  4.  
  5. Position new cylinder head gaskets onto the cylinder block.
  6.  
  7. Position cylinder heads onto head gaskets and cylinder block.
  8.  
  9. Tighten the cylinder head bolts in three steps using the sequence provided:

    Step 1: Tighten M12 cylinder head bolts, in sequence, to 25 ft. lbs. (34 Nm) and M8 bolts to 20 Nm (15 ft. lbs.).
     
    Step 2: Tighten M12 cylinder head bolts, in sequence, to 40 ft. lbs. (54 Nm) and verify M8 bolts to 15 ft. lbs. (20 Nm).
     
    Step 3: Turn M12 cylinder head bolts, in sequence, 90 degrees and tighten M8 bolts to 25 ft. lbs. (34 Nm).
     

  10.  
  11. Install pushrods and rocker arm assemblies in their original position.
  12.  
  13. Install the intake manifold and throttle body assembly.
  14.  
  15. If required, adjust spark plugs to specifications. Install the plugs.
  16.  
  17. Connect the heater hoses.
  18.  
  19. Install the fuel supply line.
  20.  
  21. Install the power steering pump.
  22.  
  23. Install the drive belt.
  24.  
  25. Install cylinder head covers.
  26.  
  27. Connect the evaporation control system.
  28.  
  29. Install the air cleaner.
  30.  
  31. Fill cooling system.
  32.  
  33. Connect the negative cable to the battery.
  34.  
  35. Start engine check for leaks.
  36.  

 
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