Chrysler Full-Size Vans 1967-1988 Repair Guide

Cylinder Head

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REMOVAL & INSTALLATION



See Figures 1 through 7



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Fig. Fig. 1: Cylinder head component location on the inline 6-cylinder engines



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Fig. Fig. 2: Inline 6-cylinder head bolt torque sequence



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Fig. Fig. 3: For cylinder head removal on L6 engines, remove the combination manifold (A) and air pipe (B)



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Fig. Fig. 4: Remove the rocker arm cover and shaft then, keeping them in order, remove the pushrods



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Fig. Fig. 5: Using a breaker bar, remove the cylinder head bolts ...



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Fig. Fig. 6: ... then lift the cylinder head off of the engine



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Fig. Fig. 7: Stuff the bores with rags, then remove any traces of the old cylinder head gasket

Inline 6-Cylinder Engines
  1. Drain the cooling system and disconnect the battery.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the 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. Remove the air cleaner and the fuel line from the carburetor.
  2.  
  3. Disconnect the accelerator linkage.
  4.  
  5. Remove the vacuum advance line from between the carburetor and the distributor.
  6.  
  7. Disconnect the cables from the spark plugs.
  8.  
  9. Disconnect the heater hose and the clamp which secures the by-pass hose.
  10.  
  11. Disconnect the water temperature sending unit.
  12.  
  13. Disconnect the exhaust pipe at the exhaust manifold flange. Disconnect the diverter valve line (if equipped) from the intake manifold and remove the air tube assembly from the cylinder head.
  14.  
  15. Remove the intake and exhaust manifolds and the carburetor as an assembly.
  16.  
  17. Remove the closed ventilation systems, the evaporative control system (if so equipped), and the valve cover.
  18.  
  19. Remove the rocker arm and shaft assembly.
  20.  
  21. Remove the pushrods and keep them in order to ensure installation in their original locations.
  22.  
  23. Remove the head bolts and remove the cylinder head.
  24.  
  25. Clean all of the gasket surfaces of the engine block and the cylinder head, an install the spark plugs.
  26.  
  27. Inspect all surfaces with a straightedge. If warpage is indicated, measure the amount. This amount must not exceed 0.00075 times the span length in any direction. For example, if a 12" span is 0.004" warped, the maximum allowable is 12X0.00075"=0.009". In this case, the head is within limits. If warpage exceeds the specified limits, either replace the head or lightly machine the head gasket surface.
  28.  

See Figure 8



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Fig. Fig. 8: When installing, follow the torque specification and tightening sequence given

To install:
  1. Coat a new cylinder head gasket with sealer, install the gasket and install the cylinder head.
  2.  
  3. Install the cylinder had bolts. Torque the cylinder head bolts to 50 ft. lbs. in the sequence indicated in the illustration. Repeat this sequence to retorque all the head bolts to specifications.
  4.  
  5. Install the pushrods in their original locations.
  6.  
  7. Install the rocker arm and shaft assembly.
  8.  
  9. Install valve cover, the closed ventilation systems, and the evaporative control system.
  10.  
  11. Install the intake and exhaust manifolds and the carburetor as an assembly.
  12.  

When installing the intake and exhaust manifold assembly, loosen the 3 bolts which secure the intake manifold to the exhaust manifold to maintain proper alignment. After installation, torque the 3 bolts in this sequence: inner bolts, then outer bolts. Refer to the manifold section, later in this information, for the proper tightening sequence. Check the valve adjustment.

  1. Connect the exhaust pipe at the exhaust manifold flange. Connect the diverter valve line (if equipped) at the intake manifold and install the air tube assembly from the cylinder head.
  2.  
  3. Connect the water temperature sending unit.
  4.  
  5. Connect the heater hose and the clamp which secures the by-pass hose.
  6.  
  7. Connect the cables at the spark plugs.
  8.  
  9. Install the vacuum advance line between the carburetor and the distributor.
  10.  
  11. Connect the accelerator linkage.
  12.  
  13. Install the air cleaner and the fuel line at the carburetor.
  14.  
  15. Fill the cooling system and connect the battery.
  16.  

V6 and V8 Engines

See Figures 9 through 17



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Fig. Fig. 9: V6 cylinder head bolt torque sequence



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Fig. Fig. 10: For cylinder head removal on V8 engines, remove the valve covers, rocker shafts and pushrods



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Fig. Fig. 11: Keep the pushrods in order. Remove the intake and exhaust manifolds



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Fig. Fig. 12: After removing the cylinder head attaching bolts, pry the head up to break it free of the engine



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Fig. Fig. 13: Lift the cylinder head off of the engine; careful, it's heavy



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Fig. Fig. 14: Remove and discard the old cylinder head gasket ...



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Fig. Fig. 15: ... and scrape the cylinder block of any remaining gasket material



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Fig. Fig. 16: Cylinder head bolt torque sequence for the 318 and 360 engines



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Fig. Fig. 17: Cylinder head bolt torque sequence for the 400 and 440 engines

  1. Drain the cooling system and disconnect the battery ground cable.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the 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. Remove the alternator, air cleaner, and fuel line.
  2.  
  3. Disconnect the accelerator linkage.
  4.  
  5. Remove the vacuum advance line from between the carburetor and the distributor. On trucks with the 360 cu. in. engine, remove the battery.
  6.  
  7. Remove the distributor cap and wires as an assembly.
  8.  
  9. Disconnect the coil wires, water temperature sending unit, heater hoses, and bypass hose. On the 360 engine remove the distributor and governor.
  10.  
  11. Remove the closed ventilation system, the evaporative control system (if so equipped), and the valve covers.
  12.  
  13. Remove the intake manifold, ignition coil, and carburetor as an assembly.
  14.  
  15. Remove the exhaust manifolds. On 360 engines tag the center bolts.
  16.  
  17. Remove the tappet chamber cover. Remove the rocker and shaft assemblies.
  18.  
  19. Remove the pushrods and keep them in order to ensure installation in their original locations. On the 360 engines remove the water pump-to-heads bolts.
  20.  
  21. Remove the head bolts from each cylinder head and remove the cylinder heads.
  22.  
  23. Clean all the gasket surfaces of the engine block and the cylinder heads. Install the spark plugs.
  24.  
  25. Inspect all surfaces with a straight edge. If warpage is indicated, measure the amount. This amount must not exceed 0.00075 times the span length in any direction. For example, if a 12" span is 0.004" warped, the maximum allowable difference is 12X0.00075=0.009". In this case, the head is within limits. If the warpage exceeds the specified limits, either replace the head or lightly machine the head gasket surface.
  26.  

To install:
  1. Coat new cylinder head gaskets with sealer, install the gaskets and install the cylinder heads.
  2.  

The number and size of the cooling passages in the 318 heads were changed during the 1976 model year. The new type gasket can be used with the old heads, but the old type gasket can't be used with the new heads.

  1. Install the cylinder head bolts. Torque the cylinder head bolts to 50 ft. lbs. in the sequence indicated. Repeat this sequence to re-torque all the cylinder head bolts to specifications.
  2.  
  3. Install the pushrods.
  4.  
  5. On the 8-360 install the water pump-to-heads bolts.
  6.  
  7. Install the rocker and shaft assemblies. Install the tappet chamber cover.
  8.  
  9. Install the exhaust manifolds.
  10.  
  11. Install the intake manifold, ignition coil, and carburetor as an assembly.
  12.  
  13. Install the closed ventilation system, the evaporative control system (if so equipped), and the valve covers.
  14.  
  15. Connect the coil wires, water temperature sending unit, heater hoses, and bypass hose. On the 360 engines, install the distributor and governor.
  16.  
  17. Install the distributor cap and wires as an assembly.
  18.  
  19. Install the vacuum advance line between the carburetor and the distributor. On trucks with the 360 engine, install the battery.
  20.  
  21. Connect the accelerator linkage.
  22.  
  23. Install the alternator, air cleaner, and fuel line.
  24.  
  25. Fill the cooling system and connect the battery ground cable.
  26.  

Diesel Engine

See Figures 18 and 19



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Fig. Fig. 18: Diesel cylinder head bolt loosening sequence



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Fig. Fig. 19: Diesel cylinder head bolt tightening sequence

  1. Drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the 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. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Disconnect the hoses from the fuel filter at the transfer pump and the injection pump. Drain the filter and remove it from the manifold.
  6.  
  7. Remove the manifold nuts and air cleaner mounting bracket attaching nuts.
  8.  
  9. Disconnect the injection lines for cylinders 3 and 6 from the injection pump.
  10.  
  11. Remove the intake manifold and gaskets from the head.
  12.  
  13. Push the exhaust manifold shield to one side.
  14.  
  15. Remove the heater hose and the bypass hose.
  16.  
  17. Remove the thermostat housing and the upper radiator hose from the water manifold. Remove the spray gasket.
  18.  
  19. Disconnect the temperature sending unit wire.
  20.  
  21. Disconnect the fuel line mounting brackets from the cylinder head and push the fuel lines aside.
  22.  
  23. Remove the three exhaust manifold bridges.
  24.  
  25. Remove the water manifold and gasket from the cylinder head.
  26.  
  27. Raise the truck and support with jackstands.
  28.  
  29. Disconnect the exhaust pipe from the exhaust manifold.
  30.  
  31. Lower the truck. Remove the exhaust manifold, heat shield and gasket.
  32.  
  33. Disconnect and remove the wire from the glow plug buss bar.
  34.  
  35. Remove the injection lines from the injection pump.
  36.  
  37. Disconnect the fuel injection line from the head. Remove the bracket and the ground strap.
  38.  
  39. Disconnect the alternator bracket and the engine lifting fixture. Push them aside.
  40.  
  41. Remove the cylinder head cover and the gasket.
  42.  
  43. Loosen and remove the cylinder head bolts in the sequence illustrated.
  44.  
  45. Lift out the rocker arm and shaft assembly.
  46.  
  47. Remove the pushrods, keeping them in order. The pushrods MUST be installed in their original location.
  48.  
  49. Remove the injector tubes, injector holds and the injectors.
  50.  
  51. Disconnect and remove the glow plug buss bar.
  52.  
  53. Remove the six glow plugs from the cylinder head.
  54.  
  55. Remove the cylinder head. Check the head for cracks, damage or evidence of water leaks. Clean all the oil, grease, scale, sealant and carbon from the head. Thoroughly clean the gasket surfaces. Also check each combustion chamber jet for cracks or melting. If a jet is cracked or melted, remove it with a pushrod inserted through a glow plug bore.
  56.  
  57. Inspect all cylinder head surfaces with a straightedge. Out-of-flatness must not exceed 0.010". If it does, a surface grinder must be used to bring the head to an out-of-flatness of less than 0.006".
  58.  

To install:
  1. Install the glow plugs in the head. Tighten them firmly.
  2.  
  3. Install the injectors, injector tubes and the injector holders in the head. Tighten the nozzle holder attaching nuts to 37 ft. lbs.
  4.  
  5. Coat the new gasket lightly with sealer. Place the gasket on the block and place the cylinder head over the dowels.
  6.  
  7. Install the cylinder head bolts and tighten them in the sequence illustrated to 90.4 ft. lbs. Do not install the head bolts which retain the rocker shaft assembly.
  8.  
  9. Install the pushrods in their original locations.
  10.  
  11. Install the rocker arm and shaft assembly. Tighten the mounting bolts, the same as the cylinder head bolts, to 90.4 ft. lbs.
  12.  
  13. Adjust the valve clearance to 0.012" at top dead center of each compression stroke.
  14.  
  15. Install the cylinder head cover and gasket.
  16.  
  17. Install the alternator bracket and the engine lifting fixture.
  18.  
  19. Connect the fuel lines to the injection pump (except nos. 3 and 6). Install the bracket and the group strap.
  20.  
  21. Install the fuel line to the transfer pump.
  22.  
  23. Install the exhaust manifold and the heat shield assembly, using a new gasket.
  24.  
  25. Raise the trunk and support it safely. Attach the exhaust pipe to the exhaust manifold.
  26.  
  27. Lower the truck and install the water manifold on the head using a new gasket.
  28.  
  29. Install the three exhaust manifold bridges.
  30.  
  31. Install the fuel lines in the bracket.
  32.  
  33. Connect the temperature sending unit wire.
  34.  
  35. Using a new gasket, install the thermostat housing. Attach the upper radiator hose to the thermostat housing.
  36.  
  37. Install the bypass and heater hoses.
  38.  
  39. Install the exhaust manifold heat shield and the exhaust manifold.
  40.  
  41. Using a new gasket and spray shield, install the air intake manifold.
  42.  
  43. Connect the injection lines from cylinders 3 and 6 to the injection pump.
  44.  
  45. Install the fuel filter to the back of the manifold.
  46.  
  47. Connect the fuel hoses.
  48.  
  49. Install the air cleaner bracket and install the air cleaner.
  50.  
  51. Fill the cooling system and connect the battery cables.
  52.  

CLEANING AND INSPECTION



  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 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, clean all bolts holes; be sure the oil passage is clean (V8 engines).
  2.  
  3. Remove all deposits from the valves with a fine wire brush or buffing wheel.
  4.  
  5. Inspect the cylinder heads for cracks or excessively burned areas in the exhaust outlet ports.
  6.  
  7. Check the cylinder head for cracks and inspect the gasket surface for burrs and nicks. Replace the head if it is cracked.
  8.  
  9. On cylinder heads that incorporate valve seat inserts, check the inserts for excessive wear, cracks, or looseness.
  10.  

RESURFACING



Cylinder Head Flatness

See Figures 20 through 24



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Fig. Fig. 20: Use a gasket scraper to remove the bulk of the old head gasket from the mating surface



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Fig. Fig. 21: An electric drill equipped with a wire wheel will expedite complete gasket removal



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Fig. Fig. 22: Check the cylinder head for warpage along these lines



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Fig. Fig. 23: Check the cylinder head for flatness across the head surface



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Fig. Fig. 24: Checks should be made both straight across the cylinder head and at both diagonals

When the cylinder head is removed, check the flatness of the cylinder head gasket surfaces.

  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 0.003" in a 6" span, or 0.006" (0.008" for the diesel) over the total length, the cylinder head must be resurfaced.
  4.  
  5. If necessary to refinish the cylinder head gasket surface, do not plane or grind off more than 0.010" (0.002" for the diesel) from the original gasket surface.
  6.  

When milling the cylinder heads of V6 and V8 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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