Chrysler Full-Size Vans 1989-1998 Repair Guide

Cylinder Head

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8 and 9

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the engine cover.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the alternator.
  6.  
  7. Remove the distributor cap and ignition wires and label them.
  8.  
  9. Remove the heat shields.
  10.  
  11. Disconnect the fuel line(s).
  12.  
  13. Disconnect the accelerator cable, speed control cable (if equipped), and transmission kickdown cable (if equipped).
  14.  
  15. Label and disconnect the coolant temperature sending unit.
  16.  
  17. Label and disconnect the heater and bypass hoses.
  18.  
  19. Label and remove all the necessary vacuum lines.
  20.  
  21. Make sure all necessary electrical connectors and vacuum lines are removed and labeled.
  22.  
  23. Remove the valve covers.
  24.  
  25. Remove the intake manifold, with the throttle body attached.
  26.  
  27. Mark and remove the rocker shaft assembly (if equipped), or the rocker arms and pivots.
  28.  
  29. Remove the exhaust manifold(s).
  30.  
  31. Remove the head bolts.
  32.  
  33. Lift the cylinder head(s) off of the engine block.
  34.  



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Fig. Fig. 1: After the retaining bolts have been removed, lift the cylinder head straight up off the block



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Fig. Fig. 2: Remove the old head gasket after the cylinder head is off the engine block



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Fig. Fig. 3: Clean the cylinder head before inspecting for cracks, wear and damage



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Fig. Fig. 4: Don't forget to clean the ports for the intake and exhaust manifolds



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Fig. Fig. 5: Also clean and inspect the engine block before assembly



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Fig. Fig. 6: Be sure to maintain the proper gasket orientation. There may be component identification markings on the gaskets to ease installation



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Fig. Fig. 7: There are different lengths of cylinder head bolts, so be sure to note each bolt's location during disassembly



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Fig. Fig. 8: The proper cylinder head torque sequence for 5.2L and 5.9L engines



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Fig. Fig. 9: The proper cylinder head torque sequence for 3.9L engines

To install:
  1. Refer to cylinder head cleaning and inspecting before installing.
  2.  
  3. Position the new cylinder head gasket(s) on the engine block.
  4.  
  5. Place the cylinder head(s) onto the gasket(s) and engine block.
  6.  
  7. Tighten, in sequence, all the head bolts to 50 ft. lbs. (68 Nm). Repeat procedure, tightening the bolts in sequence to 105 ft. lbs. (143 Nm).
  8.  
  9. Install the pushrods and rocker arm shafts or rockers and pivots in their correct positions. Tighten rocker shafts (if equipped) to 200 inch lbs. (23 Nm). Tighten rocker arms (if equipped) to 21 ft lbs. (28 Nm).
  10.  
  11. Install the intake manifold.
  12.  
  13. Install the valve covers.
  14.  
  15. Replace the vacuum hoses to their correct locations.
  16.  
  17. Replace all electrical connectors in their correct locations.
  18.  
  19. Install the heater and the bypass hoses.
  20.  
  21. Connect the accelerator cable, speed control cable (if equipped), and transmission kickdown cable(if equipped).
  22.  
  23. Connect the fuel line(s).
  24.  
  25. Install the heat shields.
  26.  
  27. Install the distributor cap and ignition wires.
  28.  
  29. Install the alternator.
  30.  
  31. Install the air cleaner assembly.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Refill with the proper coolant mixture, and bleed the cooling system.
  36.  
  37. Check for leaks.
  38.  
  39. Install the engine cover.
  40.  

 
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