Chrysler Neon 1995-1999 Repair Guide

Cylinder Head

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REMOVAL & INSTALLATION



See Figures 1 through 18

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure, as outlined in Fuel System of this guide.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Remove the air cleaner inlet duct and air cleaner. Tag and disconnect all vacuum lines, electrical wiring and fuel lines from the throttle body.
  8.  
  9. Remove the throttle linkage.
  10.  
  11. Remove the accessory drive belts, as outlined in General Information & Maintenance .
  12.  
  13. Disconnect the power brake vacuum hose from the intake manifold.
  14.  
  15. Raise and safely support the vehicle, then separate the exhaust pipe from the manifold. Carefully lower the vehicle.
  16.  
  17. Unbolt the power steering pump and set aside. Do NOT disconnect the fluid lines!
  18.  
  19. Detach the ignition coil pack wiring connector, then remove the coil pack and bracket from the engine.
  20.  
  21. Detach the cam sensor and fuel injector electrical connectors.
  22.  



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Fig. Fig. 1: Detach the cam position and other necessary connectors



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Fig. Fig. 2: Unfasten the bolts securing any brackets attached to the head ...



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Fig. Fig. 3: ... then remove the bracket from the head

  1. For 1996-99 vehicles, remove the intake manifold.
  2.  
  3. For SOHC engines, remove the timing belt and camshaft sprocket.
  4.  
  5. For DOHC engines, remove the timing belt, timing belt tensioner and camshaft sprocket. Remove the inner timing belt cover.
  6.  
  7. Remove the rocker arm (valve) cover.
  8.  



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Fig. Fig. 4: Remove the retainers, then remove the rocker arm (valve) cover

  1. For SOHC engine, remove the rocker arm shaft assemblies.
  2.  



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Fig. Fig. 5: Remove the intake rocker arm shaft assembly ...



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Fig. Fig. 6: ... then remove the exhaust rocket arm shaft assembly from the cylinder head

  1. For DOHC engines, remove the camshaft and cam follower assemblies.
  2.  
  3. For SOHC engines, if necessary, remove the oil separator assembly bolts, then remove the oil separator.
  4.  



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Fig. Fig. 7: Remove the oil separator assembly retaining bolts, then remove the assembly

  1. For SOHC engines, unfasten the hose clamps, then disconnect the heater hoses. Remove any remaining hoses or lines.
  2.  



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Fig. Fig. 8: Unfasten the clamps, then disconnect the heater hoses



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Fig. Fig. 9: Remove any remaining lines or hoses

  1. Use a ratchet to unfasten the cylinder head bolts, working from the center outward, then remove the cylinder head from the engine block.
  2.  



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Fig. Fig. 10: Loosen the cylinder head bolts, starting from the center and working outward

  1. The cylinder head bolts must be inspected before they can be reused. If the threads of bolts are stretched, they must be replaced. Check for thread stretching by holding a scale or other straight edge against the threads. If all the threads do not contact the scale, the bolts must be replaced.
  2.  



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Fig. Fig. 11: Remove the cylinder head bolts and inspect their condition in order to determine if they can be reused



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Fig. Fig. 12: If they are reusable, fabricate a holder to keep the bolts in their original positions for installation



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Fig. Fig. 13: It can be advantageous to have an assistant help you lift the cylinder head off the engine



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Fig. Fig. 14: Remove and discard the cylinder head gasket. NEVER reuse this gasket!


WARNING
Use only a plastic scraper to clean the mating surfaces. NEVER use metal, as this may gouge the metal surfaces and cause leaks!

  1. Cover the combustion chambers, then use a plastic scraper to thoroughly and carefully clean the engine block and cylinder head mating surfaces.
  2.  



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Fig. Fig. 15: With rags stuffed into the combustion chambers, use a gasket scraper to carefully clean the engine block surface



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Fig. Fig. 16: While you have the head on a workbench, thoroughly clean the gasket mating surfaces, then inspect for damage

  1. The cylinder head must be cleaned and inspected prior to installation. Please refer to the engine reconditioning portion of this guide for further details and information.
  2.  

To install:
  1. Positon a new gasket on the engine block, then place the cylinder head over the gasket.
  2.  
  3. Apply a thin coat of engine oil to the cylinder head bolt threads. The 4 short bolts 4.33 in. (110mm) are installed in positions 7, 8, 9 and 10, as shown in the accompanying figure.
  4.  



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Fig. Fig. 17: Always use a torque wrench to tighten the head bolts, making sure to follow the proper sequence



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Fig. Fig. 18: Cylinder head bolt tightening sequence

  1. For SOHC engines, tighten the cylinder head bolts, in the sequence shown, to the following specifications:
    1. Step 1: Tighten the bolts to 25 ft. lbs. (34 Nm).
    2.  
    3. Step 2: Tighten the bolts to 50 ft. lbs. (68 Nm).
    4.  
    5. Step 3: Loosen, then re-tighten the bolts to 50 ft. lbs. (68 Nm).
    6.  
    7. Step 4: Tighten all bolts an additional 1 / 4 turn. Do NOT use a torque wrench for this step.
    8.  

  2.  
  3. For DOHC engines, tighten the cylinder head bolts, in the sequence shown, to the following specifications:
    1. Step 1: Tighten bolts 1-6 to 25 ft. lbs. (34 Nm) and bolts 7-10 to 20 ft. lbs. (28 Nm).
    2.  
    3. Step 2: Tighten bolts 1-6 to 50 ft. lbs. (68 Nm) and bolts 7-10 to 20 ft. lbs. (28 Nm).
    4.  
    5. Step 3: Loosen, then re-tighten bolts 1-6 to 50 ft. lbs. (68 Nm) and bolts 7-10 to 20 ft. lbs. (28 Nm).
    6.  
    7. Step 4: Tighten all bolts an additional 1 / 4 turn. Do NOT use a torque wrench for this step.
    8.  

  4.  
  5. The remainder of installation is the reverse of the removal procedure.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Fill the cooling system with the proper amount and type of coolant.
  10.  
  11. Use a DRB or equivalent scan tool to perform the camshaft and crankshaft timing relearn procedure, as follows:
    1. Connect the scan tool to the Data Link Connector (located under the instrument panel, near the steering column).
    2.  
    3. Turn the ignition switch ON , and access the miscellaneous screen.
    4.  
    5. Select the re-learn cam/crank option, then follow the instructions on the scan tool screen.
    6.  

  12.  

 
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