Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

Cylinder Head

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REMOVAL & INSTALLATION



4-Cylinder Engines

See Figures 1 and 2


CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure MUST be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2.  
  3. Properly relieve the fuel system pressure using the procedure in Fuel System .
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Drain and properly contain the engine coolant.
  8.  
  9. Label and disengage all vacuum hoses, lines and wiring harness connections that are required for cylinder head removal.
  10.  
  11. Disconnect the fuel line.
  12.  
  13. Disconnect the throttle linkage.
  14.  
  15. Remove the accessory drive belt(s).
  16.  
  17. Detach the power steering pump and position it aside.
  18.  
  19. Disconnect the the coil pack wiring connector. Disconnect the spark plug wires from the spark plugs. Remove the ignition coil pack unit from the engine.
  20.  
  21. Remove the cylinder head cover.
  22.  
  23. Remove the intake and exhaust manifolds, if necessary.
  24.  
  25. Remove the timing belt cover, timing belt, camshaft sprocket and rear timing belt cover, using the procedures later in this section.
  26.  
  27. Remove the rocker arm/rocker arm shaft assemblies.
  28.  
  29. Unfasten the cylinder head bolts in the reverse order of their tightening sequence, then remove the cylinder head.
  30.  

To install:

The cylinder head bolts should be checked for stretching before reuse. If the thread area of the bolt is "necked down," the bolts must be replaced with new ones. In any case, new head bolts are recommended.

  1. Thoroughly clean all parts. Clean all sealing surfaces. Use care not to scratch the aluminum cylinder head sealing surface. Check the cylinder head for flatness using a feeler gauge and a straightedge. The cylinder head must be flat within 0.004 inch (0.1mm).
  2.  
  3. Check the cylinder head for cracks or other damage.
  4.  
  5. Install a new gasket and the cylinder head to the engine block.
  6.  
  7. Be sure to oil the cylinder head bolt threads with clean engine oil. Install the cylinder head bolts, and be sure to place the four short 4.330 in. (110mm) bolts in positions 7, 8, 9 and 10. Tighten the bolts in proper sequence, as illustrated.
  8.  



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Fig. Fig. 1: Cylinder head bolt tightening sequence-2.0L SOHC engine



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Fig. Fig. 2: Cylinder head bolt tightening sequence-2.0L and 2.4L DOHC engines

  1. Tighten the bolts in 4 steps as follows:
    1. First: all bolts to 25 ft. lbs. (34 Nm).
    2.  
    3. Second: all bolts to 50 ft. lbs. (68 Nm).
    4.  
    5. Third: all bolts again to 50 ft. lbs. (68 Nm).
    6.  
    7. Fourth: all bolts an additional 1 / 4 turn.
    8.  

  2.  

Do not use a torque wrench for the fourth step.



Install the rocker arm/rocker arm shaft assemblies.
 
Install the cylinder head cover.
 
Install the timing belt rear cover and camshaft sprocket. Install the timing belt.
 
Install the timing belt cover.
 
Install the intake and exhaust manifolds, if removed.
 
Install the ignition coil pack onto the engine. Reconnect the coil pack wiring connector and the spark plug wires to the correct spark plugs.
 
Install the power steering pump.
 
Install and adjust the accessory drive belts.
 
Connect the throttle linkage.
 
Check to be sure all ducts, hoses, fuel lines and wiring harness connectors have been properly engaged.
 
Install the air cleaner assembly.
 
Fill the cooling system with a 50/50 mixture of clean ethylene glycol or other suitable antifreeze and water. A complete engine oil and filter change is also recommended.
 
Connect the negative battery cable.
 
Start the engine and check for leaks. Run the engine with the radiator cap off, so as the engine warms and the thermostat opens, coolant can be added to the radiator. When satisfied that the cooling system is full, shut the engine OFF , install the radiator cap and allow the engine to cool.
 
With the engine cool, check all fluid levels. Add coolant and oil as required. Restart the engine and test drive the vehicle to check for proper operation. 6-Cylinder Engine
 

See Figures 3 through 9

  1. Properly relieve the fuel system pressure, as described in Fuel System .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine cooling system.
  6.  
  7. Remove the timing belt and camshaft sprockets.
  8.  
  9. Label and disengage any wiring harnesses, vacuum hoses and lines that would inhibit removal of the cylinder head.
  10.  
  11. Remove the intake manifold assembly.
  12.  



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Fig. Fig. 3: Location of the water pump inlet pipe retaining bolt on the inner rear part of the front cylinder head

  1. Remove the water pump inlet pipe retaining bolt on the inner rear part of the front cylinder head.
  2.  
  3. Remove the rocker arm (valve) covers and rocker arm assemblies.
  4.  
  5. Remove the distributor assembly.
  6.  
  7. On the front cylinder head, remove the ground strap on the left end of the head.
  8.  



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Fig. Fig. 4: On the front cylinder head, remove the grounding strap

  1. Remove the exhaust manifolds and crossunder pipe.
  2.  
  3. Remove the cylinder head mounting bolts in the reverse order of their tightening sequence, and place them in numbered order through holes made in a piece of cardboard.
  4.  



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Fig. Fig. 5: Loosen each cylinder head mounting bolt



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Fig. Fig. 6: After removing each bolt, examine the threads for stretching, and replace if necessary



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Fig. Fig. 7: To insure correct installation, keep the cylinder head bolts in a piece of cardboard



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Fig. Fig. 8: With an assistant, carefully lift the cylinder head off of the engine block



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Fig. Fig. 9: Remove the cylinder head gasket

  1. Remove the cylinder head and gasket.
  2.  

To install:
  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. Check the cylinder head for flatness. End to end, the head should be no more than 0.008 inch (0.2mm) out-of-true. If the service limit is exceeded, correct to meet specifications. Note that the maximum amount of stock allowed to be removed from the cylinder head and mating cylinder block is 0.0079 inch (0.2mm). If the cylinder head cannot be made serviceable by removing this amount, replace the head.
  2.  
  3. Check that the new head gasket(s) have the proper identification marks for the engine. Position a new head gasket with the identification mark at the front top.
  4.  

Do not apply sealant to the cylinder head gasket or mating surfaces.

  1. Inspect the cylinder head bolts prior to installation. If the threads are "necked down" (stretched), the bolts should be replaced. Necking can be checked by holding a straightedge against the threads. If all of the threads do not contact the straightedge, the bolt should be replaced. In any case, all new head bolts are recommended.
  2.  
  3. Install the cylinder head straight down onto the block. Try to eliminate most of the side-to-side adjustments, as this may move the gasket out of position or damage the gasket. Before installing the bolts, the threads should be oiled with clean engine oil. Install the bolts and the special washers by hand and just start each bolt 1 or 2 turns on the threads.
  4.  

The washers must be installed correctly. The rounded shoulder of the washer denotes the face in contact with the bolt. The flat face contacts the head.

  1. Correct tightening of the cylinder head bolts requires 3 steps:
    1. Follow the tightening sequence and tighten each bolt to 62 ft. lbs. (84 Nm).
    2.  
    3. Follow the tightening sequence and tighten each bolt to 70 ft. lbs. (95 Nm).
    4.  
    5. Follow the tightening sequence and tighten each bolt to 80 ft. lbs. (108 Nm).
    6.  

  2.  
  3. Install the valve cover and gasket.
  4.  
  5. Install the exhaust manifolds and crossunder pipe.
  6.  
  7. Install the distributor assembly.
  8.  
  9. Install the intake manifold assembly.
  10.  
  11. Check to make sure that all wiring harnesses, vacuum hoses and lines are all properly connected.
  12.  

Before proceeding, double check all installation items, paying particular attention to loose hoses or hanging wires, nuts not properly tightened, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.

  1. Fill the cooling system with coolant. Changing the engine oil and filter is recommended to eliminate pollutants such as coolant in the oil.
  2.  
  3. Connect the negative battery cable. With the radiator cap off, start the engine and check for leaks of fuel, vacuum, oil or coolant. Check the operation of all engine electrical systems, as well as dashboard gauges and lights. Add coolant as the engine warms.
  4.  
  5. Perform necessary adjustments to the accelerator cable and drive belts. Allow the engine to cool and once again check and adjust the coolant level.
  6.  

 
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