Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Cylinder Head

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REMOVAL & INSTALLATION



Review the entire procedure before starting this repair. Make sure to locate the correct year, engine and model service procedure for your vehicle.


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.

1981-88 Except Premier Engines
EXCEPT 2.6L ENGINE

See Figures 1 through 7

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Fig. Fig. 1: Use a breaker bar to loosen and remove the cylinder head attaching bolts ...



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Fig. Fig. 2: ... then lift the cylinder head off of the engine



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Fig. Fig. 3: Remove the old gasket from the engine block and ...



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Fig. Fig. 4: ... clean any residual gasket material from the engine block



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Fig. Fig. 5: Make certain to tighten the cylinder head bolts with a torque wrench



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Fig. Fig. 6: Tighten the cylinder head bolts in the sequence shown-2.2L and 2.5L except Premier and 2.2L Turbo III engines



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Fig. Fig. 7: Exploded view of the solid mount compressor bracket and related torque values

  1. Disconnect the negative battery cable.
  2.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. With the engine cold, drain the cooling system. If the dipstick bracket attaches to the thermostat housing, disconnect the dipstick bracket from the thermostat housing and rotate it away from the mounting stud to disconnect it without bending it.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Label and then disconnect all lines, hoses and wires from the head, manifold and carburetor or throttle body. Before disconnecting the fuel lines on fuel injected engines, be sure to depressurize the system as described in Routine Maintenance .
  6.  
  7. Disconnect the accelerator linkage.
  8.  
  9. Remove the distributor cap.
  10.  
  11. Disconnect the exhaust pipe.
  12.  
  13. Remove the carburetor or throttle body on engines so-equipped.
  14.  
  15. Remove the intake and exhaust manifolds as described earlier. On turbo engines, remove the turbo and then remove the manifolds.
  16.  
  17. Remove the front cover.
  18.  
  19. Remove the timing belt, as described later in this section.
  20.  
  21. If equipped with air conditioning, remove the compressor from the mounting brackets and support it out of the way with wires. Remove the mounting bracket from the cylinder head. Then, if the engine is equipped with the solid mount attached to the engine block and cylinder head, perform the following:
    1. Remove the alternator pivot bolt and remove the alternator.
    2.  
    3. Remove the A/C belt idler.
    4.  
    5. If the car has a turbocharger, remove the right engine mount yoke bolt, which secures the isolator support bracket to the engine mount bracket.
    6.  
    7. Now, remove all 5 side mounting bolts-those facing the radiator.
    8.  
    9. Remove the front mounting nut and bolt (both face the fender well).
    10.  
    11. Now, rotate the bracket away from the engine and slide it on the stud until it is free.
    12.  
    13. Now, reinstall the front mounting bolt into the hole to stop the leakage of coolant.
    14.  

  22.  
  23. Remove the rocker arm cover, gaskets and seals, as described earlier in this section.
  24.  
  25. Remove the cylinder head mounting bolts in the reverse order of the tightening sequence shown in the accompanying illustration.
  26.  
  27. Lift the cylinder head off of the engine block and discard the old gasket.
  28.  
  29. Inspect the cylinder head and engine block. Clean both gasket surfaces thoroughly.
  30.  

To install:

WARNING
Turbo II engines use a unique head gasket. DO NOT use a Turbo I gasket on a Turbo II engine.

  1. Make certain all gasket surfaces are thoroughly cleaned and are free of deep nicks or scratches. Always use new gaskets and seals. Never reuse a gasket or seal, even if it looks good.
  2.  
  3. Position the head on the block, then insert bolt No. 8 and bolt No. 10 (see illustration) to align the cylinder head and gasket with the engine block.
  4.  

In the 1986 model year, the 10mm cylinder head mounting bolts were replaced with 11mm bolts marked "11'' on the head. Tighten the cylinder head mounting bolts in the order shown to specifications.

  1. For 1981-86 models with 10mm cylinder head mounting bolts, tighten the bolts, in the order shown, to the following torque values:

    Step 1-30 ft. lbs. (41 Nm)
     
    Step 2-45 ft. lbs. (61 Nm)
     
    Step 3-Once again to 45 ft. lbs. (61 Nm)
     
    Step 4-tighten each bolt an additional 1 / 4 turn
     

  2.  
  3. For 1986-88 models with 11mm cylinder head mounting bolts, tighten the bolts, in the order shown, to the following torque values:

    Step 1-45 ft. lbs. (61 Nm)
     
    Step 2-65 ft. lbs. (88 Nm)
     
    Step 3-Once again to 65 ft. lbs. (88 Nm)
     
    Step 4-tighten each bolt an additional 1 / 4 turn
     

  4.  

Note that on the 1986-88 models using the 11mm bolts, torque must reach 90 ft. lbs. (122 Nm), otherwise replace the bolt.

  1. Install the valve cover, gaskets and seals, as described earlier in this section.
  2.  
  3. If the car is equipped with air conditioning (non-solid mount compressors):
    1. Remove the front mounting bolt for the compressor installed to stop coolant leakage.
    2.  
    3. Install the A/C compressor bracket by rotating it into place in reverse of the removal procedure. Install the front mounting nut and bolt and all 5 side mounting bolts.
    4.  
    5. On turbocharged vehicles the right engine mount yoke bolt was removed. Reinstall it to secure the isolator support bracket to the engine mounting bracket. Tighten it to 75 ft. lbs. (102 Nm).
    6.  
    7. Install the A/C compressor drive belt idler pulley assembly.
    8.  
    9. Install the alternator, including the alternator pivot bolt, as described in Engine Electrical .
    10.  

  4.  
  5. For vehicles with A/C and solid mount compressors, install the solid mount compressor bracket as follows:
    1. Position the spacer onto the stud, then install the bracket on the front (2 nut) mounting stud and slide the bracket over the timing belt cover into position.
    2.  
    3. Loosen the assembly bracket-to-engine fasteners (numbered 1 through 7-refer to the accompanying illustration).
    4.  

  6.  


WARNING
The bracket fasteners must be tightened in the proper sequence and to the specified torque values.

  1. Tighten the fasteners in the following sequence: 1) bolt 1 to 30 inch lbs. (3.3 Nm), 2) nut 2 and bolt 3 to 40 ft. lbs. (54 Nm), 3) bolts 1, 4 and 5 to 40 ft. lbs. (54 Nm), 4) bolts 6 and 7 to 40 ft. lbs. (54 Nm).
  2.  
  3. Install the alternator and compressor to the bracket. Tighten the compressor mounting bolts to 40 ft. lbs. (54 Nm).
  4.  

  1. Make sure all timing marks on the crankshaft, camshaft and engine block are properly aligned. Install and adjust the timing belt, as described later in this section. The timing belt is correctly tensioned when it can be twisted only 90 degrees with the thumb and index finger midway between the camshaft and the intermediate shaft. Check to make sure tension is correct.
  2.  
  3. Install the front cover. Install the intake and exhaust manifolds (with turbocharger, if so equipped). For more information, refer to the intake and exhaust manifolds removal and installation procedures earlier in this section.
  4.  
  5. Reconnect the exhaust pipe, using a new seal, and tighten the fasteners to 21 ft. lbs. (28 Nm).
  6.  
  7. Install the distributor cap and spark plug wires.
  8.  
  9. Attach the accelerator linkage to the carburetor or throttle body, depending on the specific model.
  10.  
  11. Reattach all electrical wiring connectors, fuel and vacuum hoses, and any hoses detached during removal.
  12.  
  13. Install the air cleaner.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Fill the cooling system, as described in Routine Maintenance .
  18.  
  19. Start the engine and allow it to run until it reaches operating temperature, then check for leaks. Shut the engine OFF , allow the engine to cool and refill the cooling system as needed.
  20.  

2.6L ENGINE

See Figures 8 and 9

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Fig. Fig. 8: Exploded view of the cylinder head and related components and their recommended torque values



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Fig. Fig. 9: Tighten the cylinder head bolts in the sequence shown-to loosen the head bolts, simply reverse the order


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.

Do not perform this operation on a warm engine. Remove the head bolts in the sequence shown and in several steps. Loosen the head bolts evenly. Do not attempt to slide the cylinder head off the block, as it is located with dowel pins. Lift the head straight up and off the block.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the rocker arm cover, as described earlier in this section.
  4.  
  5. Remove the intake and exhaust manifolds. For more information, refer to the procedures earlier in this section.
  6.  
  7. Remove the timing chain cover, timing chain and camshaft sprocket, as described later in this section.
  8.  
  9. Remove the distributor, as described in Engine Electrical .
  10.  
  11. Disconnect the air feeder hoses from underneath the vehicle.
  12.  
  13. If the vehicle is equipped with power steering, unbolt the pump and move aside without disconnecting hoses. Secure the pump in place with strong cord or wire; do not allow it to hang from the fluid lines.
  14.  
  15. Remove the ground wire and dipstick tube bracket from the cylinder head.
  16.  
  17. Remove the exhaust manifold, as described earlier in this section.
  18.  
  19. Remove the cylinder head bolts in several stages (loosen the bolts in the reverse order of the tightening sequence shown). Lift the cylinder head off the engine.
  20.  

To install:
  1. Install the new gasket without sealer and in a position which allows all bolt holes and the outer border of the gasket to align with the bolt holes and outer edge of the block. Lightly oil all of the bolt threads, then install and tighten the cylinder head mounting bolts in the following steps:

    Step 1-finger-tight
     
    Step 2-35 ft. lbs. (48 Nm)
     
    Step 3-69 ft. lbs. (94 Nm)
     

  2.  
  3. Tighten the cylinder head-to-timing chain cover bolts to 13 ft. lbs. (17 Nm).
  4.  
  5. Attach the exhaust manifold to the catalytic converter, as described at the end of this section.
  6.  
  7. Install the ground wire and dipstick tube.
  8.  
  9. Install the power steering pump and belt, then adjust the belt tension. For more information, refer to Suspension & Steering for power steering procedures and for drive belt tensioning procedures.
  10.  
  11. From underneath the vehicle, install the air feeder tubes.
  12.  

Before installing the timing chain and gear, refer to the timing chain procedures located later in this section.

  1. Make certain that the engine is still at TDC on cylinder No. 1 compression stroke and that all of the timing marks on the pulleys and engine block are aligned. Install the camshaft sprocket, bolt and distributor drive gear. Make certain that the matchmarks made during removal are aligned once the timing chain is installed onto the camshaft sprocket.
  2.  
  3. Reinstall all electrical engine wiring, engine vacuum hoses and carburetor linkage.
  4.  
  5. Install the distributor and spark plug wires, as described in Engine Electrical .
  6.  
  7. Connect the upper radiator hose and heater hoses. For more information on cooling system hose procedures, refer to Routine Maintenance .
  8.  
  9. Install the rocker arm cover, as described earlier in this section.
  10.  
  11. Install the fuel pump cover bracket and water pump pulley cover.
  12.  
  13. Reconnect the PCV hose.
  14.  
  15. Install the air cleaner and reconnect all ducting and vacuum hoses securely.
  16.  
  17. Close the radiator draincock, if open, lower the vehicle and remove the wheel blocks.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Fill the cooling system, then start the engine and check for leaks. When the engine has reached operating temperature, check the ignition timing. When the engine has cooled back off, refill the cooling system, if necessary.
  22.  

1989-95 Except Premier Engines

See Figures 6 through 12

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Fig. Fig. 10: Make certain to use the correct gasket when installing the cylinder head, otherwise the engine may overheat because of a blocked coolant passage



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Fig. Fig. 11: Before installing the cylinder head bolts, make sure that they haven't stretched, or "necked'', by holding them against a straightedge and inspecting the threads as shown



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Fig. Fig. 12: Make sure to tighten the cylinder head mounting bolts in the sequence shown-2.2L Turbo III engines


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.

For this procedure, either a Special Tool C-4852 (Engine Support), or equivalent, will be necessary or the timing belt covers and timing belt must be removed. The engine support tool is used to hold the camshaft sprocket in place with the adequate amount of tension to prevent the timing belt form skipping crankshaft teeth or from falling off of the crankshaft sprocket.

  1. Relieve fuel system pressure, as described in Fuel System .
  2.  
  3. Disconnect the negative battery cable and detach it from the head.
  4.  
  5. Remove the intake and exhaust manifolds. For more details, refer to the intake and exhaust manifold procedure earlier in this section.
  6.  
  7. Remove the turbocharger, as described earlier in this section.
  8.  
  9. Perform one of the following procedures:
    1. Remove the timing belt covers and timing belt. For more information, refer to the timing belt removal and installation procedure located later in this section. OR ...
    2.  
    3. Use the engine support tool C-4852, or equivalent, to suspend the timing sprocket and belt in position. Removal and installation of the cylinder head requires separation of the camshaft sprocket from the camshaft. To maintain camshaft, intermediate shaft and crankshaft timing during service procedures, the timing belt is left indexed on the sprocket while the assembly is "suspended'' under light tension by Special Tool C-4852. When removing the sprocket from the camshaft, you must maintain adequate tension on the sprocket and belt assembly to prevent the belt from disengaging from the intermediate or crankshaft timing sprockets. For camshaft sprocket removal and installation directions, refer to the appropriate procedure later in this section.
    4.  

  10.  


WARNING
Failure to maintain adequate tension on the camshaft, intermediate shaft and crankshaft sprocket belt can result in lost engine timing. If the timing is lost, the timing belt must be removed and reinstalled according to the procedures later in this section.

  1. For 2.2L Turbo III engines with A/C, remove the A/C compressor and mounting bracket completely, as described in Chassis Electrical .
  2.  
  3. For all other engines with A/C, remove the upper compressor mounting bolts; the cylinder head can be removed with the compressor and bracket still mounted.
  4.  
  5. Remove the rocker arm cover, as described earlier in this section.
  6.  
  7. Remove the cylinder head bolts, then lift the cylinder head off of the engine.
  8.  

To install:

Since the cylinder heads are tightened using a new procedure, they should be examined before reuse. If the threads are necked down the bolts should be replaced.

  1. Check the cylinder head bolts for necking by holding a scale or straightedge against the threads. If all the threads do not contact the scale, the bolt should be replaced. Lubricate the bolt threads with clean engine oil.
  2.  

The 2.5L Turbo I engine head gasket is NOT the same as that used for the prior 2.2L Turbo I engine.

  1. Clean the cylinder head gasket mating surfaces and inspect the cylinder head and related components, as described later in this section.
  2.  

Except 2.2L Turbo III engines-Head bolt diameter is 11mm. These bolts are identified with the number "11'' on the head of the bolt. The 10mm bolts used on previous vehicles will thread into an 11mm bolt hole, but will permanently damage the cylinder block. Make sure the correct bolts are used when replacing head bolts.

2.2L Turbo III engines-The head gasket used on the Turbo III engine is unique to the engine. Make sure the replacement head gasket is identical to the original gasket before installation. Head bolt diameter is 11mm and the head bolts are unique to this engine. These bolts are identified with the number 11 on the head of the bolt and are not interchangeable with other engines. Make sure the correct bolts are used when replacing head bolts.

  1. Using new gaskets and seals, install the cylinder head to the engine. Tighten the cylinder head bolts, following the sequence shown in the accompanying illustrations, in the following steps:

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

  2.  

Bolt torque after the additional1/4turn should be over 90 ft. lbs. (122 Nm). If it isn't, replace the bolt.

  1. Install the timing belt and all related items, as described later in this section.
  2.  
  3. Install the intake and exhaust manifolds and turbocharger, if applicable. For more information, refer to these procedures earlier in this section.
  4.  
  5. On 2.2L Turbo III engines, install the air conditioning compressor and bracket to the cylinder head, as described in Chassis Electrical .
  6.  
  7. For all other engines (except 2.2L Turbo III), install the 2 upper A/C compressor bracket mounting bolts to the cylinder head. Tighten the bolts to 40 ft. lbs. (54 Nm).
  8.  
  9. Install the rocker arm covers and oil curtain or ignition cable cover, as applicable, then tighten the hold-down bolts to 105 inch lbs. (12 Nm).
  10.  
  11. Install the air cleaner assembly and all ductwork.
  12.  
  13. Refill the cooling system, then connect the negative battery cable.
  14.  
  15. Start the engine and check for leaks.
  16.  

2.5L Premier Engine

See Figures 13, 14, 15 and 16

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Fig. Fig. 13: Exploded view of the cylinder head and related components on the 2.5L Premier engine



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Fig. Fig. 14: Utilize 2 old head bolts to fabricate alignment dowels as shown for installing the cylinder head



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Fig. Fig. 15: Install the fabricated alignment dowels in the 2 opposing corners-do not tighten them in the engine block too tightly



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Fig. Fig. 16: Tighten the cylinder head retaining bolts in the sequence shown

  1. Relieve the fuel system pressure, as described in Fuel System .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system. For more details, refer to Routine Maintenance .
  6.  
  7. Loosen and remove the accessory drive belt.
  8.  
  9. Remove the bolts attaching the air conditioning compressor and, without disconnecting the pressure lines, move the compressor aside. Secure the compressor aside with strong cord or wire; do not allow the compressor to hang from the refrigerant lines.
  10.  
  11. Disconnect the upper radiator hose and the heater hoses.
  12.  
  13. Remove the rocker arm cover, as described earlier in this section.
  14.  
  15. Remove the rocker arm retaining bolts. Remove the rocker arm assemblies and the pushrods. For more information, refer to the rocker arm/shaft procedures earlier in this section.
  16.  

Make certain when removing valve train components, to mark or store them, so that they will be installed in their original positions.

  1. Remove the intake and exhaust manifolds, as described earlier in this section.
  2.  
  3. Remove the cylinder head bolts, then lift the cylinder head off of the engine block.
  4.  
  5. Clean all gasket material from mating surfaces.
  6.  

To install:
  1. Using old head bolts or equivalent (such as 2 pieces of threaded stock available at most hardware stores), fabricate 2 alignment dowels. Cut the heads off the bolts and cut a slot in one end for a screwdriver. Install the alignment dowels at bolt locations No. 8 and No. 10.
  2.  
  3. Position the new cylinder head gasket on the engine block with the numbers facing UP .
  4.  

The cylinder head bolts used on the 2.5L Premier engine can only be used a total of 2 times. Therefore the bolts can only be reused once before new bolts are necessary. If the cylinder head bolts removed from the engine have dabs of paint on their heads, they have already been reused (used twice) and must be discarded; new bolts must be purchased. If the cylinder head bolts do have paint on them, they have not yet been used twice and may be reused at this time. If reusing the cylinder head bolts paint the bolt heads so that they can be identified later on as already reused. New bolts, however, are always recommended.

  1. Place the cylinder head on the engine block and install the bolts. Following the proper sequence (shown in the accompanying illustration), tighten the cylinder head bolts in the following steps:
    1. Step 1-tighten all 10 bolts to 22 ft. lbs. (30 Nm).
    2.  
    3. Step 2-tighten all 10 bolts to 45 ft. lbs. (61 Nm)
    4.  
    5. Step 3-retighten all 10 bolts to 45 ft. lbs. (61 Nm)
    6.  
    7. Torque bolts No. 1 through6 to 110 ft. lbs. (149 Nm)
    8.  
    9. Torque bolt No. 7 to 100 ft. lbs. (136 Nm)
    10.  
    11. Torque bolts No. 8 through 10 to 110 ft. lbs. (149 Nm)
    12.  
    13. Retighten each bolt to its proper torque. Pay special attention to bolt No. 7; it should not be overtightened.
    14.  

  2.  
  3. Install the valve train components in their original sequence. Using a new gasket, install the rocker cover.
  4.  
  5. Connect radiator and heater hoses which were removed.
  6.  
  7. Install the air conditioning compressor, tighten the mounting bolts to 20 ft. lbs. (27 Nm).
  8.  
  9. Route the accessory drive belt and adjust for proper tension.
  10.  
  11. Connect the battery cable and fill the cooling system.
  12.  
  13. Run the engine and check for leaks.
  14.  

CLEANING & INSPECTION



See Figure 17



Click image to see an enlarged view

Fig. Fig. 17: Check the cylinder head for flatness across the head surface

  1. With the valves installed to protect the valve seats, remove deposits from the combustion chambers and valve heads with a scraper and a wire brush. Be careful not to damage the aluminum cylinder head gasket surface. After the valves are removed, clean the valve guide bores with a valve guide cleaning tool. Using cleaning solvent to remove dirt, grease and other deposits and clean all bolts holes.
  2.  
  3. Using a straightedge, inspect the cylinder head gasket surface for excessive warpage. The cylinder head should be resurfaced if the warpage exceeds 0.004 in. (0.1mm) for Chrysler engines, or 0.002 in. (0.051mm) per 6 in. (152.4mm) for the 2.5L Premier engine. Inspect the cylinder head from corner-to-corner, side-to-side and end-to-end for warpage.
  4.  
  5. Remove all deposits from the valves with a fine wire brush or buffing wheel.
  6.  
  7. Inspect the cylinder heads for cracks or excessively burned areas in the exhaust outlet ports.
  8.  
  9. Check the cylinder head for cracks and inspect the gasket surface for burrs and nicks. Replace the head if it is cracked.
  10.  

RESURFACING



See Figure 17

When the cylinder head is removed, check the flatness of the cylinder head gasket surfaces. Since the tools required for resurfacing a cylinder head are extremely expensive and the necessary skills are important, refer to a reputable machine shop for cylinder head refinishing specifications and procedures.

  1. Place a straightedge across the gasket surface of the cylinder head. Using feeler gauges, determine the clearance at the center of the straightedge.
  2.  
  3. If warpage exceeds 0.004 in. (0.1mm) over the total length for Chrysler engines, or 0.002 in. (0.051mm) per 6 in. (152.4mm) for the 2.5L Premier engine, the cylinder head must be resurfaced.
  4.  

 
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