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    Chrysler Concorde/Intrepid/LHS/New Yorker/Vision 1993-1997

    Cylinder Head

    Print

    REMOVAL & INSTALLATION




    CAUTION
    The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

    3.3L Engine

    See Figures 1 through 13



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    Fig. Fig. 1: Remove the rocker arm and shaft assembly



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    Fig. Fig. 2: Pull the pushrods out of the head ...



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    Fig. Fig. 3: ... then place in the exact order (position) on a piece of card board



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    Fig. Fig. 4: Remove the 9 bolts holding the head onto the block, on top ...



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    Fig. Fig. 5: ... on the sides ...



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    Fig. Fig. 6: ... and don't forget the one in the front corner



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    Fig. Fig. 7: Now the head assembly can be separated from the block ...



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    Fig. Fig. 8: ... and the gasket discarded (note the cylinder bores have rags to keep dirt from entering)



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    Fig. Fig. 9: Thoroughly clean and dry the mating surfaces of the head and block



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    Fig. Fig. 10: When installing the end gasket, the markings on the gasket must be seen



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    Fig. Fig. 11: Inspect the cylinder head bolts for necking (stretching), you can see a difference in these bolts



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    Fig. Fig. 12: Cylinder head bolt torque sequence-3.3L engine



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    Fig. Fig. 13: With the stamped steel retainers in the forward positions, tighten to 250 inch lbs. (28 Nm)

    The cylinder heads on this engine are aluminum alloy, retained by nine bolts. Valve seats and guides are inserts. Use care when handling alloy parts. In addition, the cylinder head bolts are torque-to-yield type which stretch during the torque process. Head bolts must be checked carefully before reuse. New head bolts are recommended.

    1. Release the fuel system pressure using the recommended procedure.
    2.  
    3. Disconnect negative battery cable.
    4.  
    5. Drain the cooling system.
    6.  
    7. Remove the intake manifold and throttle body assemblies using the recommended procedure. Use care when handling the intake manifold gasket. It is made of very thin metal and could cause cuts if carelessly handled.
    8.  
    9. Disconnect the coil wires, sending unit wire, heater hoses and bypass hose.
    10.  
    11. Remove the evaporation control system, closed ventilation system and the cylinder head covers.
    12.  
    13. Remove the exhaust manifold(s) from the engine.
    14.  
    15. Remove rocker arm and shaft assemblies. Remove pushrods and identify to assure installation in original location.
    16.  
    17. Loosen and remove the nine head bolts in the reverse order of the tightening sequence from the cylinder head.
    18.  
    19. Lift the head off the cylinder block.
    20.  

    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 head for flatness. End to end, the head should be within 0.002 inch (0.051mm) normally with 0.008 inch (0.203mm) the maximum allowed out of true. The total thickness allowed to be removed from the head and block is 0.008 inch (0.203mm) maximum.
    2.  
    3. Place a new head gasket on the cylinder block with the identification marks facing upward. Do not use sealer on factory type gasket.
    4.  
    5. Inspect the cylinder head bolts for necking (stretching) by holding a straightedge against the threads of each bolt. If all of the threads are not contacting the the scale, the bolt should be replaced. New head bolts are recommended.
    6.  


    WARNING
    Due to the cylinder head bolt torque method used, it is imperative that the threads of the bolts be inspected for necking (stretching) prior to installation. If the threads are necked down, the bolt should be replaced. Failure to do so may result in parts failure or damage.

    1. Install the cylinder head bolts. Tighten bolts Nos. 1 through 8 following the proper sequence as listed below:
    2.  



    Step 1-45 ft. lbs. (61 Nm)
     
    Step 2-65 ft. lbs. (88 Nm)
     
    Step 3- (again) 65 ft. lbs. (88 Nm)
     
    Step 4-additional 1 / 4 -turn
     

    Do not use a torque wrench for Step 4. Inspect the bolt torque after tightening. The torque should be over 90 ft. lbs. (122 Nm). If not, replace the cylinder head bolt.

    1. Tighten bolt No. 9 to 25 ft. lbs. (33 Nm) only after bolts 1-8 have been tightend to specification.
    2.  
    3. Inspect the pushrods and replace worn or bent rods. Install the pushrods, rocker arm and shaft assemblies with the stamped steel retainers in the forward positions. Tighten the rocker shaft retainers to 250 inch lbs. (28 Nm).
    4.  

    The rocker arm shaft should be tightend down slowly, starting with the centermost bolts. Allow 20 minutes tappet bleed down time after installation of the rocker shafts before engine operation.

    1. Install the cylinder head covers with new gaskets in place. Tighten the retainers to 105 inch lbs. (12 Nm).
    2.  

    The factory type intake manifold gasket is made of very thin metal and is very sharp. Handle with care or personal injury may occur.

    1. Using all new gaskets, install the intake manifold, throttle body, air intake plenum and exhaust manifold, using the recommended procedure and following the proper torque sequences.
    2.  
    3. Connect all exhaust and fuel connections.
    4.  
    5. Reconnect the coil wires, sending unit wire, heater hoses and bypass hose.
    6.  
    7. Install the air intake hose.
    8.  
    9. Change the engine oil and oil filter.
    10.  
    11. Refill and bleed the cooling system.
    12.  
    13. Reconnect the negative battery cable and run the vehicle with the radiator cap off so coolant can be added as required until the thermostat opens. Watch for leaks and unusual engine noises that might indicate a problem. Fill the radiator completely.
    14.  
    15. Once the vehicle has cooled, recheck the coolant and oil level.
    16.  

    3.5L Engine

    See Figures 14, 15, 16, 17 and 18

    This engine uses aluminum alloy cylinder heads. Use care when working with light alloy components. The heads are common to either cylinder bank, but in practice, cylinder heads should be returned to the side of the engine from which it was removed. Removal of a cylinder head involves removal of the timing belt. Great care is required to install the belt, paying attention to all valve timing marks. Please note that camshaft removal on this engine does require the removal of the cylinder head.


    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. Release the fuel system pressure using the recommended procedure.
    2.  
    3. Disconnect negative battery cable.
    4.  
    5. Drain the cooling system.
    6.  
    7. Remove the radiator and cooling fan assemblies.
    8.  
    9. Remove the air cleaner assembly and the intake manifold plenum. Cover the lower intake manifold during service.
    10.  
    11. Remove the accessory drive belts.
    12.  
    13. Remove the crankshaft damper using the proper puller.
    14.  
    15. Remove the engine valve covers.
    16.  
    17. Remove the timing belt covers.
    18.  



    Click image to see an enlarged view

    Fig. Fig. 14: Cylinder head exploded view-3.5L engine

    1. Mark the timing belt running direction for installation. Align the camshaft sprockets with the marks on the rear covers. Remove the timing belt and tensioner.
    2.  
    3. Pre-load the timing belt tensioner as follows:
    4.  

    1. Place tensioner in a vise the same way it is mounted on the engine.
    2.  
    3. Slowly compress the plunger into the tensioner body.
    4.  
    5. When the plunger is compressed into the tensioner body, install a pin through the body and plunger to retain plunger in place until the tensioner is installed.
    6.  

    1. Hold the camshaft sprocket with 36mm box wrench, loosen and remove the sprocket retaining bolt and washer.
    2.  

    To remove the camshaft sprocket retainer bolt while the engine is in the vehicle, it may be necessary to raise that side of the engine due to the length of the retainer bolt. The right bolt is 8.370 inches (212.6mm) long, while the left bolt is 10.0 inches (253mm) long. These bolts are not interchangeable and their original location during removal should be noted.

    1. Remove the camshaft sprocket from the camshaft. The camshaft sprockets are not interchangeable from side to side.
    2.  
    3. Remove the intake manifold assembly using the recommended procedure.
    4.  
    5. Remove the rear timing belt cover to cylinder head fasteners. If the right timing belt cover is to be removed, there are O-rings located behind it for the water pump passages.
    6.  



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    Fig. Fig. 15: Remove the rear timing belt cover-to-cylinder head, note the bolt locations



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    Fig. Fig. 16: Right side belt cover water pump and O-rings

    1. Remove the cylinder head mounting bolts in the reverse order of the tightening sequence. Remove the cylinder head.
    2.  

    To install:
    1. Thoroughly clean and dry the mating surfaces of the head and block.
    2.  

    When cleaning the cylinder head and block mating surfaces, do not use a metal scraper because the soft aluminum surfaces could be cut or damaged. Instead, use a scraper made of wood or plastic.

    1. Check the cylinder head for cracks, damage or engine coolant leakage. Check the head for flatness. End to end, the head should be within 0.002 inch (0.051mm) normally with 0.008 inch (0.203mm) the maximum allowed out of true. The resurface limit is 0.008 inch (0.203mm) maximum, the combined total dimension of stock removal from the cylinder head if any and block top surface.
    2.  
    3. Place a new head gaskets on the cylinder block locating dowels being sure the gasket is on the correct side.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 17: Correct positioning for the head gaskets-3.5L engine

    1. Inspect the cylinder head bolts for necking by holding a straightedge against the threads of each bolt. If all of the threads are not contacting the the scale, the bolt should be replaced.
    2.  


    WARNING
    Due to the cylinder head bolt torque method used, it is imperative that the threads of the bolts be inspected for necking prior to installation. If the threads are necked down, the bolt should be replaced. Failure to do so may result in parts failure or damage. New bolts are always recommended.



    Click image to see an enlarged view

    Fig. Fig. 18: Cylinder head bolt torque sequence-3.5L engine

    1. Install the cylinder head into position on the engine block and over the dowels. Install the cylinder head bolts, lubricating the threads with clean engine oil prior to installation. Tighten bolts following the proper sequence as listed below:
    2.  



    Step 1-45 ft. lbs. (61 Nm)
     
    Step 2-65 ft. lbs. (88 Nm)
     
    Step 3-again, 65 ft. lbs. (88 Nm)
     
    Step 4-additional 1 / 4 -turn
     

    Do not use a torque wrench for Step 4. Inspect the bolt torque after tightening. The torque should be over 90 ft. lbs. (122 Nm). If not, replace the cylinder head bolt.

    1. Install the rear timing belt cover bolts and tighten as follows:
    2.  



    M6 bolts-105 inch lbs. (12 Nm)
     
    M8 bolts-21 ft. lbs. (28 Nm)
     
    M10 bolts-40 ft. lbs. (54 Nm)
     

    1. Install the intake manifold assembly and tighten bolts following the proper sequence to 21 ft. lbs. (28 Nm).
    2.  

    The following procedure can only be used when the camshaft sprockets have been loosened or removed from the shafts.

    1. When the camshaft sprockets are loosened or removed, the camshafts must be timed to the engine. Install the Camshaft Alignment Tools 6642-A or exact equivalent, to the rear of the cylinder heads.
    2.  
    3. Install both camshaft sprockets to the appropriate shafts. The left camshaft sprocket has the DIS pickup as part of the sprocket.
    4.  
    5. Apply threadlocking compound to the threads of the camshaft sprocket retainer bolts and install to the appropriate shafts. The right bolt is 8.380 inch (213.00mm) long, while the left bolt is 10.0 inch (254.00mm) long. These bolts are not interchangeable. Do not tighten the bolts at this time. The camshaft marks should be between the marks on the cover.
    6.  
    7. Place the crankshaft sprocket to the TDC mark on the oil pump housing. Install the timing belt starting at the crankshaft sprocket and working in a counterclockwise direction.
    8.  
    9. After the belt is installed around the last sprocket keep tension on the belt until it is past the tensioner pulley.
    10.  
    11. Holding the tensioner pulley against the belt, install the tensioner housing and tighten to 250 inch lbs. (28 Nm)
    12.  
    13. When the tensioner is in place pull the retainer pin to allow tensioner to extend to the pulley bracket.
    14.  
    15. Install a dial indicator in No. 1 cylinder to check Top Dead Center (TDC) of the piston. Rotate the crankshaft until the piston is exactly at TDC.
    16.  
    17. Hold the right camshaft sprocket hex with a 36mm box wrench and tighten the right camshaft sprocket bolt to 75 ft. lbs. (102 Nm). Turn the sprocket bolt an additional 90 degrees.
    18.  
    19. Hold the left camshaft sprocket hex with a 36mm box wrench and tighten the left camshaft sprocket bolt to 85 ft. lbs. (115 Nm). Turn the sprocket bolt an additional 90 degrees.
    20.  
    21. Remove the dial indicator.
    22.  
    23. Remove the camshaft alignment tools from the back of the cylinder heads and install the cam covers and new O-rings. Tighten the fasteners to 20 ft. lbs. (27 Nm). Repeat this procedure on the other camshaft.
    24.  
    25. Install the timing belt covers and crankshaft damper. Tighten the crankshaft damper bolt to 85 ft. lbs. (115 Nm).
    26.  
    27. Install the valve covers and tighten bolts to 105 inch lbs. (12 Nm).
    28.  
    29. Install the spark plug tube nut and O-ring. Tighten the nut to 60 inch lbs. (7 Nm). Install spark plugs and tighten to 20 ft. lbs. (28 Nm).
    30.  
    31. Install the air conditioning compressor to the mounting bracket. Tighten the mounting bracket bolts to 30 ft. lbs. (41 Nm).
    32.  
    33. Reconnect the spark plug wires to the correct spark plugs.
    34.  
    35. Install the accessory drive belts. Adjust to the proper tension.
    36.  
    37. Install the intake manifold plenum using the recommended procedure.
    38.  
    39. Install the air cleaner assembly.
    40.  
    41. Install the radiator and cooling fan assemblies.
    42.  
    43. Check to be sure that all hoses, wiring connectors, cables, fluid and vacuum lines are reconnected.
    44.  
    45. Change the engine oil and oil filter.
    46.  
    47. Refill and bleed the cooling system.
    48.  
    49. Reconnect the negative battery cable, run the vehicle with the radiator cap off so coolant can be added as required until the thermostat opens. Watch for leaks and for unusual engine noises. Fill the radiator completely as required.
    50.  
    51. Once the vehicle has cooled, recheck the coolant and oil level.
    52.  

    CLEANING & INSPECTION



    One the complete valve train has been removed from the cylinder head(s), the head itself can be inspected, cleaned and machined (if necessary). Set the head(s) on a clean work space, so the combustion chambers are facing up. Begin cleaning the chambers and ports with a hardwood chisel or other non-metallic tool (to avoid nicking or gouging the chamber, ports, and especially the valve seats). Chip away the major carbon deposits, then remove the remainder of carbon with a wire brush fitted to an electric drill. A fine-bristled rifle bore cleaning brush will also work well.

    Be sure that the carbon is actually removed, rather than just burnished.

    After decarbonizing is completed, take the head(s) to a machine shop and have the head hot tanked. In this process, the head is lowered into a hot chemical bath that very effectively cleans all grease, corrosion, and scale from all internal and external head surfaces. Also have the machinist check the valve seats and recut them if necessary. When you bring the clean head(s) home, place them on a clean surface. Completely clean the entire valve train with solvent.

    RESURFACING



    Machine shop work requires special training and equipment, it is best to send the cylinder head assembly to a reputable machine shop for this kind of repair (valve job).

    Cylinder Head Flatness

    See Figure 19



    Click image to see an enlarged view

    Fig. Fig. 19: Checks should be made both straight across the head and a both diagonals

    When the cylinder head is removed, check the flatness of the cylinder head gasket surfaces. Refer to a machine shop for cylinder head refinishing specifications and procedure as necessary.

    1. Place a straightedge across the gasket surface of the cylinder head. Using feeler gauges, determine the clearance at the center of the straightedge. If warpage exceeds 0.00075 inch (0.019mm) times the span length in inches (25.4mm) in any direction, either replace the head or have the head machined by a reputable automotive machine shop. If the head is to be machined flat, the maximum pre-machining warpage allowed is also 0.008 inch (0.2mm).
    2.  
    3. Have the head resurfaced by a reputable automotive machine shop if the warpage exceeds the standard dimension, but does not exceed the maximum allowable dimensions.
    4.  

    When milling the cylinder heads of V6 engines, the intake manifold mounting position is altered, and must be corrected by milling the manifold flange a proportionate amount. Consult an experienced machinist about this.

     
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