Chrysler Full-Size Trucks 1997-2000 Repair Guide

Cylinder Head

Print

REMOVAL & INSTALLATION




WARNING
The engine must be cold before attempting to remove the cylinder head. Loosening head bolts on a hot engine may cause component damage.

Read the procedures before starting to get a thorough understanding of the tools and equipment needed. Many cylinder head components are precision-machined pieces that need to be cleaned and carefully inspected before installation. Refer to "Engine Reconditioning" for this information.

Common Steps

The following steps are common to most models. Refer to individual procedures for particulars for each vehicle.

  1. Disconnect the battery negative cable(s).
  2.  
  3. Drain the coolant from engine and radiator.
  4.  
  5. Remove the upper radiator hose.
  6.  
  7. Remove the air cleaner assembly and duct work.
  8.  
  9. Disconnect control cables from the throttle body: typically, throttle, cruise control and kickdown cables.
  10.  
  11. Disconnect all of the hoses and vacuum lines from the intake and exhaust manifolds and from the valve cover(s). This will normally include crankcase ventilation and evaporative control systems.
  12.  
  13. If equipped with A/C, unbolt the compressor from the mounting bracket and place it aside. Unbolt and remove the compressor bracket.
  14.  
  15. Mark and disconnect the spark plug wires. On the 4.7L, remove the ignition coils.
  16.  
  17. Loosen or remove the spark plugs.
  18.  
  19. Remove any heat shields located on the exhaust manifolds.
  20.  
  21. Disconnect the exhaust manifold from the head.
  22.  
  23. Remove the accessory drive belt.
  24.  
  25. Remove the alternator (except 2.5L).
  26.  
  27. Disconnect the heater hoses.
  28.  
  29. Disconnect the coolant temperature sending unit(s) on the intake manifold.
  30.  
  31. Disconnect sensor wires from intake manifold sensors.
  32.  
  33. Disconnect throttle body electrical connectors.
  34.  
  35. Depressurize and disconnect the fuel line.
  36.  
  37. Disconnect all of the fuel system and injector electrical connectors.
  38.  
  39. Remove the intake manifold complete with fuel system components.
  40.  
  41. Remove the cylinder head cover(s).
  42.  
  43. Remove the rocker arms and pushrods, if fitted.
  44.  
  45. Check for and disconnect ground straps, wiring harness or other electrical connections on the head(s).
  46.  

To install:

  1. Use new gaskets throughout.
  2.  
  3. Do NOT use sealants or gasket compounds on head gasket.
  4.  
  5. Observe the cylinder head tightening sequences and proper fastener torque. Head bolts are tightened in a cross pattern starting near the center of the head and working outwards. On some engines, a multiple-step tightening sequence is recommended.
  6.  


NOTE
Bolt tightness should always get a final check after the sequence is completed.

  1. Be careful when installing rocker arms that the piston is not at TDC.
  2.  
  3. In some cases, installation may be made easier by fabricating locating dowels from old head bolts. Cut off the hex, slot the end to accept a screwdriver, and fit at each end of the block to locate the head during installation.
  4.  



Click image to see an enlarged view

Fig. Locating dowels made from old head bolts may ease head installation

2.5L Engine
  1. Carry out the "Common Steps" above.
  2.  
  3. Unbolt the power steering pump bracket and set pump and bracket aside. It is not necessary to disconnect the hoses.
  4.  
  5. Remove the cylinder head bolts.
  6.  


NOTE
If the bolts have a dab of paint on the heads, they have been removed before. Use new ones when assembling. If they do not have the dab of paint, mark them after installation.

  1. Remove the cylinder head and gasket.
  2.  

To install:

  1. Remove all carbon, gasket material, etc., from all of the mating surfaces.
  2.  
  3. Decarbonize piston crowns, exhaust ports and clean intake ports and water passages.
  4.  
  5. Refer to the appropriate illustration for the cylinder head bolt tightening sequence. Be sure to tighten head bolts in gradually and evenly according to the pattern provided.
  6.  
  7. Use thread locking compound on the threads of bolt 7 .
  8.  
  9. Tighten all cylinder head bolts in the order shown to 22 ft. lbs. (30 Nm).
  10.  
  11. Tighten all cylinder head bolts to 45 ft. lbs. (61 Nm).
  12.  
  13. Tighten bolts 1 through 6 to 110 ft. lbs. (149 Nm).
  14.  
  15. Tighten bolt 7 to 100 ft. lbs. (136 Nm).
  16.  
  17. Tighten bolts 8 , 9 , and 10 to 110 ft. lbs. (149 Nm).
  18.  
  19. Carry out a final torque check on all bolts.
  20.  
  21. Mark reused head bolts with a dab of paint.
  22.  
  23. The remainder of the procedure is the reverse of disassembly.
  24.  



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.5L engine

V-6, V-8, V-10 OHV Engines
  1. Carry out the "Common Steps" above.
  2.  
  3. Remove the distributor cap or coil packs (V-10).
  4.  
  5. Remove the lower intake manifold (V-10).
  6.  
  7. Remove the cylinder head bolts.
  8.  
  9. Remove the cylinder head and gasket.
  10.  

To install:

  1. Reverse the removal procedure.
  2.  
  3. On 6-and 8-cylinder engines, tighten the head bolts, in the order shown in the appropriate illustration, in two steps: first to 50 ft. lbs. (68 Nm), and then 105 ft. lbs. (143 Nm) on the second step.
  4.  
  5. On V-10 engines, tighten the head bolts, in the order shown in the appropriate illustration, in two steps: first to 43 ft. lbs. (58 Nm), and then 105 ft. lbs. (143 Nm) on the second step.
  6.  



Click image to see an enlarged view

Fig. Removing the cylinder head-5.2L shown



Click image to see an enlarged view

Fig. Check gasket for marks or properties that aid in installation



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-V-6 engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-5.2L, 5.9L gasoline engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-V-10 engine

4.7L Engine

A special timing chain locking tool (P/N 8515) is required for this procedure.

  1. Carry out the "Common Steps" above.
  2.  
  3. Remove the engine cooling fan and shroud.
  4.  
  5. Remove the oil fill housing.
  6.  
  7. Remove the power steering pump.
  8.  
  9. Before disconnecting the timing chains alignment of crankshaft and cam sprocket is required for both cylinder heads
  10.  
  11. Rotate the crankshaft so that the damper 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.
  12.  
  13. Remove the crankshaft damper. Remove the timing chain cover.
  14.  
  15. Lock the secondary timing chains to the idler sprocket with Timing Chain Locking tool 8515.
  16.  
  17. Matchmark the secondary timing chains to the camshaft sprockets.
  18.  
  19. Remove the secondary timing chain tensioner.
  20.  
  21. Remove the cylinder head access plug.
  22.  
  23. Remove the secondary chain guide.
  24.  
  25. Remove the retaining bolt and the camshaft drive gear.
  26.  


WARNING
Do NOT allow the engine to rotate. Damage to the valve train can occur.

  1. Remove the cylinder head bolts, head and gasket.
  2.  


NOTE
Each cylinder head is retained by ten 11mm bolts and four 8mm bolts. Do NOT neglect the four smaller bolts at the front of the cylinder head.

  1. Repeat the procedure with the other cylinder head.
  2.  

To install:

  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 thread locking compound.
  6.  


NOTE
Refer to the illustration for the cylinder head torque sequence illustration

  1. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows:
    1. Step 1: Bolts 1 through 10 to 15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: Bolts 1 through 10 to 35 ft. lbs. (47 Nm)
    4.  
    5. Step 3: Bolts 11 through 14 to 18 ft. lbs. (25 Nm)
    6.  
    7. Step 4: Bolts 1 through 10 , plus an additional 1 / 4 (90º) turn.
    8.  
    9. Step 5: Bolts 11 through 14 to 22 ft. lbs. (30 Nm).
    10.  

  2.  
  3. Install the camshaft sprockets. Align the crankshaft with the TDC mark and the secondary chain matchmarks, and then tighten the bolts to 90 ft. lbs. (122 Nm).
  4.  
  5. Install the secondary timing chain guides, head access plugs, secondary chain tensioners. Refer to the timing chain procedure.
  6.  
  7. Remove the timing chain locking tool P/N 8515.
  8.  
  9. Tighten the crankshaft damper to 130 ft. lbs. (175 Nm).
  10.  



Click image to see an enlarged view

Fig. Before unbolting the cam sprockets, first align the damper mark with the "TDC" mark (arrows); check alignment of cam sprockets as illustrated-4.7L



Click image to see an enlarged view

Fig. After the damper mark is aligned, check that the cam sprocket "V8" marks are at 12 o'clock. If not, turn the crankshaft 360º and recheck-4.7L



Click image to see an enlarged view

Fig. Apply thread sealer to bolts 11 through 14 ; oil the rest and tighten in the order given in the steps outlined in the text-4.7L

Diesel

CAUTION
A crane or other dedicated lifting device designed for the job is required to remove the cylinder head.

  1. Carry out the "Common Steps" above.
  2.  
  3. Remove the turbocharger.
  4.  
  5. Remove the engine harness-to-cylinder head attaching bolt at the front of the head.
  6.  
  7. Remove the engine harness ground fastener at the front of the head below the thermostat housing.
  8.  
  9. Remove the throttle linkage cover. Remove the six accelerator pedal position sensor assembly-to-cylinder head bracket bolts and secure the entire assembly out of the way.
  10.  
  11. Disconnect the APPS connector.
  12.  
  13. Remove the intake air grid heater wires from the grid heater.
  14.  
  15. Remove the oil level indicator tube attaching bolt from the air inlet housing.
  16.  
  17. Remove the charge air cooler-to-air inlet housing pipe.
  18.  
  19. Remove the air inlet housing and intake grid heater from the intake manifold cover.
  20.  
  21. Remove the engine lift bracket at the rear of the cylinder head.
  22.  
  23. Remove the high pressure fuel lines. See "Fuel System" for details.
  24.  
  25. remove the fuel filter-to-injection pump low-pressure line.
  26.  
  27. Disconnect the water-in-fuel and fuel heater connectors.
  28.  
  29. Remove the fuel filter assembly-to-manifold cover bolts and remove the filter assembly from the truck.
  30.  
  31. Disconnect the IAT and MAP sensors.
  32.  
  33. Remove the cylinder head cover(s).
  34.  
  35. Remove the rocker arms and pushrods.
  36.  
  37. Remove the fuel return line banjo fitting at the rear of the cylinder head.
  38.  
  39. Reinstall the engine lift bracket.
  40.  
  41. Remove the 26 cylinder head bolts.
  42.  
  43. Using a suitable lifting device, remove the cylinder head from the vehicle.
  44.  

To install:

  1. Reverse the removal procedure.
  2.  

Cylinder head bolts should be replaced with new ones if they have been removed before or if stretched. A cylinder head capscrew length gauge may be included with replacement head gaskets.

  1. Install head gasket with the P/N facing upward.
  2.  
  3. Tighten the head bolts in the order shown. Tighten in steps with torque given in the specifications charts. Note that 12-valve and 24-valve engines differ in this regard.
  4.  



Click image to see an enlarged view

Fig. APPS assembly (5) showing lever (1), mounting bolts (2), wiring harness clip (3), and calibration screws (4)



Click image to see an enlarged view

Fig. MAP (1) and IAT (2) sensor locations



Click image to see an enlarged view

Fig. Check head bolt stretch against the gauge, if included in the head gasket kit



Click image to see an enlarged view

Fig. Diesel cylinder head bolt tightening sequence. Tighten in steps. See "Torque Specifications" charts for details

 
label.common.footer.alt.autozoneLogo