Dodge Colt/Challenger/Conquest/Vista 1971-1989 Repair Guide

Cylinder Head

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The timing chain/belt and the cam gear must be removed and secured together after the engine is turned to No. 1 cylinder at the TDC position. The exception being the 1410cc and 1468cc engines (see following paragraphs). The cylinder head bolts on the 1410cc, 1468cc, 1597cc and 1997cc engines require a 5 / 16 inch Allen socket to remove. On 1994cc and 2555cc engines the cylinder head bolts are hex headed.

REMOVAL





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Fig. Fig. 1 Head bolt loosening sequence-1410, 1468, 1597 and 1997cc engines



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Fig. Fig. 2 Head bolt loosening sequence-2555cc engine



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Fig. Fig. 3 Loosen the cylinder head bolts in the correct sequence



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Fig. Fig. 4 It is recommended to replace the cylinder head bolts with new ones



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Fig. Fig. 5 Lift the cylinder head off the block and set aside



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Fig. Fig. 6 Place clean rags in the open cylinders, then remove the old gasket and clean the mating surfaces

Never remove the cylinder head unless the engine is absolutely cold, or the cylinder head will warp.

  1. Turn the crankshaft to put No. 1 piston at top dead center with timing marks aligned.
  2.  
  3. Disconnect the negative cable from the battery. Remove the air cleaner assembly and the attached breather hoses. Drain the radiator coolant. Remove the upper radiator hose and disconnect the heater hoses.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted to 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 fuel line from the carburetor and fuel pump. On fuel injected engines, discharge the fuel pressure and disconnect the fuel lines. Disconnect the accelerator linkage, distributor vacuum lines, purge valve and water temperature gauge wire.
  2.  
  3. Remove the spark plug wires, spark plugs and the fuel pump. It is necessary to remove the distributor, mark the mounting flange location (see ).
  4.  
  5. Remove the exhaust manifold.
  6.  
  7. Remove the intake manifold (see intake manifold removal).
  8.  

During the following procedures, do not turn the crankshaft from TDC.

1410cc and 1468cc Engines
  1. Remove the timing belt cover. Be sure the knockout pin (cam sprocket) is at 12 o'clock and the cam sprocket mark and cylinder head pointer aligned at 3 o'clock.
  2.  
  3. Loosen the timing belt tensioner mounting. Move the tensioner toward the water pump and secure it in that position. Remove the timing belt from the camshaft pulley.
  4.  

The camshaft pulley need not be removed, and the timing belt may be left mounted on the crankshaft pulley.

  1. Remove the rocker arm cover.
  2.  

1971-76 1597cc Engine W/O Silent Shaft
  1. Remove the rocker arm cover.
  2.  
  3. Position the crankshaft sprocket dowel pin between 1 and 2 o'clock, with the crank shaft pulley notch aligned with the timing mark T at the front of the timing chain case.
  4.  
  5. Matchmark the timing chain and the timing mark on the camshaft sprocket with white paint. Lock the chain to the sprocket with mechanics wire.
  6.  
  7. Remove the sprocket from the camshaft.
  8.  

1597cc Engine With or Without Silent Shaft and 1997cc Engines
  1. Align the timing mark on the upper under cover of the timing belt with that of the camshaft sprocket.
  2.  
  3. Matchmark the timing belt and the timing mark on the camshaft sprocket with a felt tip pen.
  4.  
  5. Remove the sprocket and insert a 50mm piece of timing belt or other material between the bottom of the camshaft sprocket and the sprocket holder on the timing belt lower front cover, to hold the sprocket and belt so that the valve timing will not be changed.
  6.  
  7. Remove the timing belt upper under cover and the rocker arm cover.
  8.  

1973-75 1994cc Engine
  1. Remove the rocker arm cover.
  2.  
  3. Position the camshaft sprocket dowel pin at the 12 o'clock position with the crankshaft pulley notch aligned with the TDC or T mark on the timing indicator scale.
  4.  
  5. Match the timing chain and the timing mark on the camshaft sprocket with white paint. Lock the chain to the sprocket with mechanics wire.
  6.  
  7. Remove the sprocket from the camshaft.
  8.  

1976-83 1994cc and 2555cc Engines
  1. Remove the rocker arm cover.
  2.  
  3. Position the camshaft sprocket dowel pin at the 12 o'clock position with the crankshaft pulley notch aligned with the timing mark T at the front of the timing chain case.
  4.  
  5. Match the timing chain with the timing mark on the camshaft sprocket.
  6.  
  7. Remove the camshaft sprocket bolt, distributor, gear and the sprocket from the camshaft.
  8.  

All Engines
  1. Loosen and remove the cylinder head bolts in two or three stages to avoid cylinder head warpage.
  2.  
  3. Remove the cylinder head from the engine block. Lift the head from the engine, locator pins in the engine block will prevent sliding.
  4.  

INSTALLATION





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Fig. Fig. 7 Head bolt tightening sequence-1410, 1468, 1597 and 1997cc engines



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Fig. Fig. 8 Head bolt tightening sequence-1994 and 2555cc engines

  1. Clean the cylinder head and block mating surfaces and install a new cylinder head gasket.
  2.  
  3. Position the cylinder head on the engine block, engage the dowel pins and install the cylinder head bolts.
  4.  
  5. Tighten the head bolts in three stages and then torque to specifications.
  6.  
  7. On 1977-85 1597 and 1997cc engines, install the timing belt upper under cover.
  8.  
  9. Locate the camshaft in the original position. Pull the camshaft sprocket, belt or chain up and install on the camshaft.
  10.  

If you experience any difficulty while installing the timing chain, belt or sprocket: refer to the timing chain/belt installation section of this section.

  1. If the dowel pin and the dowel pin hole do not line up between the sprocket and the spacer or camshaft, move the camshaft by bumping either of the two projections (provided at the rear of number two cylinder exhaust lobe of the camshaft) with a light hammer or other tool until the hole and pin align. Be certain that the crankshaft does not turn.
  2.  
  3. Install the camshaft sprocket bolt and distributor drive gear and tighten. (The gear is used on 1994cc and 2555cc engines from 1976).
  4.  
  5. Install the timing belt upper front cover and spark plug cable support or timing belt cover, depending on which model you are working on.
  6.  
  7. Apply sealant to the intake manifold gasket on both sides. Position the gasket and install the intake manifold. Tighten the nuts to specification. Be sure that no sealant enters the jet air passages on models that are equipped with jet valves.
  8.  
  9. Install the exhaust manifold gaskets and the exhaust manifold. Tighten the nuts to specifications.
  10.  
  11. Connect the exhaust pipe to the exhaust manifold assembly and tighten the nuts to specifications. Install the fuel pump and purge valve.
  12.  
  13. Install the water temperature gauge wire, heater hoses and the upper radiator hose. Connect the fuel lines, accelerator linkage and vacuum hoses. Install the distributor, spark plugs and spark plug wires, etc.
  14.  
  15. Fill the cooling system. Connect the negative battery cable.
  16.  
  17. Adjust the valve clearances to the cold engine specifications. (Refer to ).
  18.  
  19. Install the gasket on the rocker arm cover and temporarily install the cover on the engine.
  20.  
  21. Start the engine and allow it to reach normal operating temperature. Stop the engine and remove the rocker arm cover.
  22.  
  23. Adjust the valves to hot engine specifications.
  24.  
  25. Reinstall the rocker arm cover and tighten securely.
  26.  
  27. Install the air cleaner, hoses purge valve hose and any other removed unit.
  28.  

CLEANING AND INSPECTION





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Fig. Fig. 9 Use a gasket scraper to remove the bulk of the old head gasket from the mating surface



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Fig. Fig. 10 Check the cylinder head for flatness across the head surface



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Fig. Fig. 11 Checks should be made both straight across the cylinder head and at both diagonals



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Fig. Fig. 12 Check the cylinder head for warpage along the center using a straightedge and a feeler gauge



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Fig. Fig. 13 Be sure to check for warpage across the cylinder head at both diagonals

With the cylinder head removed from the engine, the rocker arm assemblies and camshaft removed, the valves, valve springs and valve stem oil seals can not be serviced.

Since the machining of valve seats and valves, and the insertion of new valve guides or valve seats may tax the experience and equipment resources of the car owner, it is suggested that the cylinder head be taken to an automotive machine shop for rebuilding.

  1. Remove the cylinder head from the car engine (see Cylinder Head Removal). Place the head on a workbench and remove any manifolds that are still connected. Remove all rocker arm assembly parts, if still installed and the camshaft (see Camshaft Removal).
  2.  
  3. Turn the cylinder head over so that the mounting surface is facing up and support evenly on wooden blocks.
  4.  
  5. Use a scraper and remove all of the gasket material and carbon stuck to the head mounting surface. Mount a wire carbon removal brush in an electric drill and clean away the carbon on the valve heads and head combustion chambers.
  6.  

When scraping or decarbonizing the cylinder head, take care not to damage or nick the gasket mounting surface or combustion chamber.

  1. Number the valve heads with a permanent felt-tipped marker for cylinder location.
  2.  

RESURFACING



If the cylinder head is warped, resurfacing by an automotive machine shop, will be required. After cleaning the gasket surface, place a straightedge across the mounting surface of the head. Using feeler gauges, determine the clearance at the center and along the length between the head and straightedge. Measure clearance at the center and along the lengths of both diagonals. If warpage exceeds 0.08mm in a 152mm span, or 0.15mm over the total length the cylinder head must be resurfaced.

 
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