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Cylinder Head: Installation: Installation

WARNING: This page is about a different variant/trim than selected.
Fig 1: Checking Cylinder Head Bolts For Stretching (Necking)
GC0084105Courtesy of CHRYSLER GROUP, LLC
CAUTION:

The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

  1. Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
    Fig 2: VVT Filter
    GC0084106Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.

    CAUTION:

    Always replace the variable valve timing filter screen (3) when servicing the head gasket or engine damage could result.

  2. Replace the variable valve timing filter screen (3).
    Fig 3: Cylinder Head RTV
    GC0084107Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    When using RTV, the sealing surfaces must be clean and free from grease and oil.

    NOTE:

    When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.

  3. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder block as shown in illustration.
    Fig 4: Cylinder Head Gasket RTV
    GC0084108Courtesy of CHRYSLER GROUP, LLC
  4. Position the new cylinder head gasket on engine block with the part number facing up. Ensure gasket is seated over the locating dowels in block.
  5. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder head gasket as shown in illustration.
    NOTE:

    The head must be installed within 15 minutes before the RTV skins.

  6. Position cylinder head onto engine block.
    Fig 5: Cylinder Head Bolt Identification
    GC0084061Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    This engine was built with 2 different style cylinder head bolts. Each style bolt requires a different torque value. The bolts can be identified by the short bolt head (1) and the long bolt head (2).

  7. Measure the bolt head from the washer to the top of the bolt head. The short bolt head (1) measures 8 mm (5/16") and the long bolt head (2) measures 13 mm (1/2").
  8. Identify whether your engine has the short head design (1) or the long head design (2).
    Fig 6: Washers Must Be Installed With Bevel Edge Up Towards Bolt Head
    GC0098610Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The front two cylinder head bolts do not have captured washers. The washers must be installed with the bevel edge (1) up towards the bolt head.

    Fig 7: Front Head Bolt Washers
    GC0084109Courtesy of CHRYSLER GROUP, LLC
  9. Install washers (1) for the front two cylinder head bolts with the beveled edge facing up.
    Fig 8: Cylinder Head Bolt Tightening Sequence
    GC0098611Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Before installing the cylinder head bolts, lubricate the threads with clean engine oil.

  10. Install the cylinder head bolts and tighten in the sequence shown in illustration.
    Fig 9: Cylinder Head Bolt Identification
    GC0084061Courtesy of CHRYSLER GROUP, LLC
  11. If your bolt has the short head (1), use the following torque specifications:
    • First: All to 30 N.m (25 ft. lbs.)
    • Second: All to 61 N.m (45 ft. lbs.)
    • Third: All to 61 N.m (45 ft. lbs.)
    • Fourth: All an additional 90°
      CAUTION:

      Do not use a torque wrench for the Fourth step.

  12. If your bolt has the long head (2), use the following torque specifications:
    • First: All to 30 N.m (25 ft. lbs.)
    • Second: All to 73 N.m (54 ft. lbs.)
    • Third: All to 73 N.m (54 ft. lbs.)
    • Fourth: All an additional 90°
      CAUTION:

      Do not use a torque wrench for the Fourth step.

  13. Clean excess RTV from timing chain cover sealing surface.
    Fig 10: Coolant Temperature Sensor, Capacitor Electrical Connector & Coolant Adapter
    GC0082401Courtesy of CHRYSLER GROUP, LLC
  14. Install coolant adapter (3) with new seals. Tighten bolts to 18.1 N.m (159 in. lbs.).
    Fig 11: Camshaft Cap Bearing Identification
    GC0082414Courtesy of CHRYSLER GROUP, LLC
  15. The front camshaft bearing cap (1) is numbered (2) either one, two, or three, this corresponds to the select fit front exhaust camshaft bearing to use.
    Fig 12: Camshaft Bearing Identification
    GC0082415Courtesy of CHRYSLER GROUP, LLC
  16. Install the corresponding select fit front exhaust camshaft bearing (1).
  17. Oil all of the camshaft journals with clean engine oil.
    Fig 13: Camshaft Timing Marks
    GC0082464Courtesy of CHRYSLER GROUP, LLC
  18. Position exhaust camshaft (1) and intake camshaft (2) on bearing journals in the cylinder head.
  19. Align camshaft timing marks (3) so that they are facing each other and are in line with the cylinder head cover sealing surface.
    CAUTION:

    Install the front intake and exhaust camshaft bearing cap last. Ensure that the dowels are seated and follow torque sequence or damage to engine could result.

    NOTE:

    If the front camshaft bearing cap is broken, the cylinder head MUST be replaced.

    Fig 14: Camshaft Cap Torque Sequence
    GC0082418Courtesy of CHRYSLER GROUP, LLC
  20. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 9.5 N.m (85 in. lbs.) in the sequence shown in illustration.
    Fig 15: Front Cam Cap Removal/Tightening Sequence
    GC0082419Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Verify that the exhaust bearing shells are correctly installed, and the dowels are seated in the head, prior to torquing bolts.

  21. Install the front intake and exhaust bearing cap and tighten bolts to 25 N.m (18 ft. lbs.) in the sequence shown in illustration.
    Fig 16: Timing Drive System
    GC0082465Courtesy of CHRYSLER GROUP, LLC
  22. Install timing chain guide (4) and tighten bolts to 12 N.m (105 in. lbs.).
  23. Install the moveable timing chain pivot guide (6) and tighten bolt to 12 N.m (105 in. lbs.).
  24. Install timing chain (2) and tensioner (5). Refer to CHAIN AND SPROCKETS, TIMING, INSTALLATION .
  25. Install timing chain cover, engine mount, pulleys and accessory drive belt. Refer to COVER(S), ENGINE TIMING, INSTALLATION .
    Fig 17: Removing/Installing Cylinder Head Cover Bolts In Sequence
    GC0082402Courtesy of CHRYSLER GROUP, LLC
  26. Install cylinder head cover and ignition coils. Refer to COVER(S), CYLINDER HEAD, INSTALLATION .
    Fig 18: Ground Strap
    GC0098612Courtesy of CHRYSLER GROUP, LLC
  27. Install exhaust manifold. Refer to MANIFOLD, EXHAUST, INSTALLATION .
  28. Install ground strap (1) at right rear of cylinder head if equipped.
    Fig 19: Intake Manifold Bolt Removal & Tightening Sequence
    GC0082457Courtesy of CHRYSLER GROUP, LLC
  29. Install intake manifold, vacuum lines and fuel rail. Refer to MANIFOLD, INTAKE, INSTALLATION .
    Fig 20: Upper Radiator Hose Support
    GC0098613Courtesy of CHRYSLER GROUP, LLC
  30. Install upper radiator hose retaining bracket bolt (1).
    Fig 21: Ignition Coils, Air Hose, Fuel Line, Injectors & PCV Hose
    GC0084062Courtesy of CHRYSLER GROUP, LLC
  31. Connect coil (1) and injector (4) electrical connectors.
    Fig 22: Coolant Temperature Sensor, Capacitor Electrical Connector & Coolant Adapter
    GC0082401Courtesy of CHRYSLER GROUP, LLC
  32. Connect electrical connectors to coolant temperature sensor (1), camshaft position sensors, oil temperature sensor, variable valve timing solenoids, MAP sensor, manifold tuning valve, ignition interference suppressor (2) and electronic throttle control.
    Fig 23: Windshield Washer Reservoir, Power Steering Reservoir & Coolant Reservoir
    GC0098614Courtesy of CHRYSLER GROUP, LLC
  33. Install power steering pump reservoir (2). Tighten mounting screw to 12 N.m (106 in. lbs.).
  34. Install windshield washer reservoir (1).
  35. Install coolant recovery reservoir (3). Tighten mounting bolts to 4 N.m (35 in. lbs.).
    Fig 24: Air Cleaner Body, Air Inlet Tube & Make-Up Air Hose
    GC0145278Courtesy of CHRYSLER GROUP, LLC
  36. Push down on the air cleaner body (1) to engage the pins into the grommets.
  37. Install the support bracket bolt to the strut tower and tighten to 10 N.m (89 in. lbs.).
  38. Install the air inlet tube (2) to the air cleaner body (1).
  39. Connect the make-up air hose (3) to the air cleaner body.
    Fig 25: Electrical Connectors, PCM, Three Mounting Bolts & Ground Wire
    GC0145274Courtesy of CHRYSLER GROUP, LLC
  40. Install the mounting bolt (3) with ground wire (1) and tighten to 12 N.m (106 in. lbs.).
  41. Connect and lock the electrical connectors (2).
    Fig 26: Retainers, Fresh Air Inlet Duct & Air Cleaner Body
    GC0145275Courtesy of CHRYSLER GROUP, LLC
  42. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  43. Install the fresh air inlet duct (3) on the air cleaner body (1) and lock the retainers (2).
    Fig 27: Engine Cover - 2.4L
    GC0082403Courtesy of CHRYSLER GROUP, LLC
  44. Fill cooling system. Refer to STANDARD PROCEDURE .
  45. Install new oil filter and fill engine with oil.
  46. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for leaks and correct fluid levels.
  47. Install engine cover (1).
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