Dodge Omni/Horizon/Rampage 1978-1989 Repair Guide

Cylinder Head

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REMOVAL & INSTALLATION



1.6L Engine

WARNING
The cylinder head must be cool before removing to avoid distortion.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by 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 assembly.
  2.  



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Fig. Fig. 1 Exploded view of the 1.6L cylinder head

  1. Disconnect all lines, hoses and wires from the head, manifold and carburetor.
  2.  
  3. Disconnect the accelerator linkage.
  4.  



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Fig. Fig. 2 Remove the cylinder head bolts in this sequence

  1. Remove the intake and exhaust manifolds.
  2.  
  3. If equipped with air conditioning, remove the compressor from the mounting brackets and support it out of the way. DO NOT remove the hoses from the compressor.
  4.  
  5. Remove the valve cover as previously described.
  6.  



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Fig. Fig. 3 When installing a new gasket, place the gasket over the dowels with the words DESSUS or TOP facing up

  1. Loosen the cylinder head bolts evenly, beginning at the ends and working towards the center.
  2.  
  3. Tie the rocker arm assembly together with safety wire or equivalent.
  4.  
  5. Remove the bolts and lift the rocker arm assembly off the cylinder head.
  6.  



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Fig. Fig. 4 Tighten the cylinder head bolts in this sequence

  1. Label all the pushrods so they be reinstalled in their original locations and remove them from the cylinder head.
  2.  
  3. Lift off the cylinder head and discard the gasket.
  4.  

To install:

  1. Make certain the gasket surfaces are thoroughly cleaned and are free of nicks or scratches.
  2.  


WARNING
Always use a new head gasket and make certain the word DESSUS or TOP faces up when the gasket is laid on the engine block.

  1. Lubricate the head bolt threads with engine oil and install through the rocker shaft brackets.
  2.  
  3. Screw the bolts down finger-tight while checking to see that each rocker adjusting screw engages its pushrod.
  4.  
  5. Tighten the head bolts in progressive steps to 52 ft. lbs. (71 Nm). Start and run the engine to normal operating temperature, allow to cool down and retighten as described above.
  6.  
  7. Check valve clearance and adjust as necessary.
  8.  
  9. Install the air conditioning compressor.
  10.  
  11. Install the intake and exhaust manifolds.
  12.  
  13. Connect the accelerator linkage.
  14.  
  15. Connect all lines, hoses and wires to the head, manifold and carburetor.
  16.  
  17. Install the air cleaner assembly.
  18.  
  19. Fill the cooling system.
  20.  
  21. Connect the negative battery cable.
  22.  

1.7L Engine

The engine should be cold before the cylinder head is removed. The head is retained by 10 socket head bolts.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  



Click image to see an enlarged view

Fig. Fig. 5 Exploded view of the 1.7L cylinder head


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by 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 assembly.
  2.  
  3. Disconnect all lines, hoses and wires from the head, manifold and carburetor.
  4.  
  5. Disconnect the accelerator linkage.
  6.  
  7. Remove the distributor cap.
  8.  
  9. Disconnect the exhaust pipe.
  10.  
  11. Remove the carburetor.
  12.  
  13. Remove the intake and exhaust manifolds.
  14.  
  15. Remove the upper portion of the front cover.
  16.  
  17. Turn the engine by hand until all gear timing marks are aligned.
  18.  
  19. Loosen the drive belt tensioner and slip the belt off the camshaft gear.
  20.  


WARNING
The camshaft timing mark is on the back of the gear and is properly positioned when it is in line with the left corner of the camshaft cover at the head.

  1. If equipped with air conditioning, remove the compressor from the mounting brackets and support it out of the way with wires. Remove the mounting brackets from the head.
  2.  
  3. Remove the valve cover, gaskets and seals.
  4.  



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Fig. Fig. 6 When installing the gasket, the word OBEN should face up



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Fig. Fig. 7 Cylinder head bolt tightening sequence

  1. Remove head bolts in reverse order of the tightening sequence.
  2.  
  3. Lift off the head and discard the gasket.
  4.  

To install:

  1. Make certain all gasket surfaces are thoroughly cleaned and are free of deep nicks or scratches.
  2.  


WARNING
Always use new gaskets and seals. Never reuse a gasket or seal, even if it looks good.

  1. When positioning the head on the block, insert bolts 8 and 10 to align the head.
  2.  
  3. Tighten bolts in the order. Bolts should be tightened to 30 ft. lbs. (41 Nm). in rotation, then tightened to 60 ft. lbs. (81 Nm). When all bolts are at 60 ft. lbs. (81 Nm), tighten each 1 / 4 turn more in sequence.
  4.  
  5. Install the valve cover, gaskets and seals.
  6.  
  7. Make sure all timing marks are aligned before installing the drive belt. The drive belt is correctly tensioned when it can be twisted 90° with the thumb and index finger midway between the camshaft and intermediate shaft.
  8.  
  9. If equipped with air conditioning, install the compressor.
  10.  
  11. Install the upper portion of the front cover.
  12.  
  13. Install the intake and exhaust manifolds.
  14.  
  15. Install the carburetor.
  16.  
  17. Connect the exhaust pipe.
  18.  
  19. Install the distributor cap.
  20.  
  21. Connect the accelerator linkage.
  22.  
  23. Connect all lines, hoses and wires to the head, manifold and carburetor.
  24.  
  25. Install the air cleaner assembly.
  26.  
  27. Fill the cooling system.
  28.  
  29. Connect the negative battery cable.
  30.  

2.2L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by 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 assembly.
  2.  



Click image to see an enlarged view

Fig. Fig. 8 Exploded view of the 2.2L cylinder head

  1. Disconnect all lines, hoses and wires from the head, manifold and carburetor.
  2.  
  3. Disconnect the accelerator linkage.
  4.  
  5. Remove the distributor cap.
  6.  
  7. Disconnect the exhaust pipe.
  8.  
  9. Remove the carburetor or throttle body.
  10.  


WARNING
If equipped with fuel injection, release the fuel system pressure.

  1. Remove the intake and exhaust manifolds.
  2.  
  3. Remove the upper portion of the front cover.
  4.  
  5. Turn the engine by hand until all gear timing marks are aligned.
  6.  



Click image to see an enlarged view

Fig. Fig. 9 Cylinder head bolt tightening sequence

  1. Loosen the drive belt tensioner and slip the belt off the camshaft gear.
  2.  
  3. If equipped with air conditioning, remove the compressor from the mounting brackets and support it out of the way with wires. Remove the mounting brackets from the head.
  4.  
  5. Remove the valve cover, gaskets and seals.
  6.  
  7. Remove head bolts in reverse order of tightening sequence.
  8.  
  9. Lift off the head and discard the gasket.
  10.  

To install:

  1. Make certain all gasket surfaces are thoroughly cleaned and are free of deep nicks or scratches. Always use new gaskets and seals. Never reuse a gasket or seal, even if it looks good.
  2.  
  3. When positioning the head on the block, insert bolts 8 and 10 to align the head. Tighten bolts in the order shown to specifications.
  4.  
  5. On models through 1986 tighten to 45 ft. lbs. (61 Nm) plus 1 / 4 turn. On 1987-89 models tighten in a four step sequence. 1st step tighten all to 45 ft. lbs. (61 Nm), 2nd step all to 65 ft. lbs. (88 Nm), 3rd step all to 65 ft. lbs. (88 Nm) again and 4th step 1 / 4 turn more.
  6.  
  7. Make sure all timing marks are aligned before installing the drive belt. The drive belt is correctly tensioned when it can be twisted 90° with the thumb and index finger midway between the camshaft and the intermediate shaft.
  8.  
  9. If equipped with air conditioning, install the compressor.
  10.  
  11. Install the upper portion of the front cover.
  12.  
  13. Install the intake and exhaust manifolds.
  14.  
  15. Install the carburetor or throttle body.
  16.  
  17. Connect the exhaust pipe.
  18.  
  19. Install the distributor cap.
  20.  
  21. Connect the accelerator linkage.
  22.  
  23. Connect all lines, hoses and wires to the head, manifold and carburetor.
  24.  
  25. Install the air cleaner assembly.
  26.  
  27. Fill the cooling system.
  28.  
  29. Connect the negative battery cable.
  30.  

CLEANING AND INSPECTION




WARNING
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 now 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.



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Fig. Fig. 10 Use a gasket scraper to remove the bulk of the old head gasket from the mating surface



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Fig. Fig. 11 An electric drill equipped with a wire wheel will expedite complete gasket removal

  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.  


WARNING
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 lengths of both diagonals. If warpage exceeds 0.003 in. (0.08mm) in a 6 in. (152mm) span, or 0.006 in. (0.15mm) over the total length, the cylinder head must be resurfaced.



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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

 
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