300M, Concorde, Intrepid, LHS, 1998-2004 - Cylinder Head
Removal & Installation
2.7L
Engines
NOTE
Place shop rags in the openings to prevent debris from entering
the engine.
Negative battery cable
Accessory drive belts
Crankshaft damper
Intake plenum, lower intake manifold and exhaust manifold
Valve and timing chain covers
Coolant connections for the cylinder heads
WARNING
Be sure the head bolts 9-11 are removed before attempting to
remove the cylinder head, the head and/or block may be damaged.
Primary timing chain
Camshaft bearing caps, gradually, in the reverse order of the
tightening sequence
Camshafts
Cylinder head bolts in reverse order of installation starting with
bolts 11-9, then 8-1
Cylinder head(s)
To install:
Fig. Camshaft bolt tightening sequence-2.7L engine
Fig. Cylinder head bolt tightening sequence-2.7L engine
continue...
WARNING
Due to the cylinder head bolt torque method used, it is imperative
that the bolt threads be inspected for necking (stretching) prior to
installation. If the threads are necked down, the bolt should be
replaced. Failure to do so may result in parts failure or damage.
Camshafts, timing chain and sprockets
Water connections to the cylinder head
Valve and timing chain covers
Crankshaft damper and torque the center bolt to 125 ft. lbs. (170
Nm)
Lower intake manifold and intake plenum
Exhaust manifolds
Accessory drive belts
Negative battery cable
continue...
3.2L & 3.5L Engines
Before servicing the vehicle, refer to the Precautions section.
This engine uses aluminum alloy cylinder heads. Use care when
working with light alloy components. The heads are common to either
cylinder bank, but in practice a cylinder head should be returned to the
side of the engine from which it was removed. Removal of a cylinder
head involves removal of the timing belt. Great care is required to
install the belt, paying attention to all valve timing marks. Please
note that camshaft removal on this engine does require the removal of
the cylinder head.
Properly relieve the fuel system pressure.
Drain the cooling system.
Remove or disconnect the following:
NOTE
Cover the lower intake manifold during service.
NOTE
Mark the timing belt running direction for installation. Align the
camshaft sprockets with the marks on the rear covers.
Negative battery cable
Radiator and cooling fan assemblies
Air cleaner assembly and intake manifold
plenum
Accessory drive belts
Crankshaft damper using the proper puller
Engine valve covers
Timing belt covers
Timing belt and tensioner
Pre-load the timing belt tensioner as follows:
Place tensioner in a vise the same way it is mounted on the
engine.
Slowly compress the plunger into the tensioner body.
Once the plunger is compressed, install a pin through the body and
plunger to retain it in place until the tensioner is installed.
Hold the camshaft sprocket with a 36mm box wrench, loosen and
remove the sprocket retaining bolt and washer.
NOTE
To remove the camshaft sprocket retainer bolt while the engine is
in the vehicle, it may be necessary to raise that side of the engine due
to the length of the retainer bolt. The right bolt is 8.370 in.
(212.6mm) long, while the left bolt is 10.0 in. (253mm) long. These
bolts are not interchangeable and their original location during removal
should be noted.
Remove or disconnect the following:
NOTE
The camshaft sprockets are not interchangeable.
NOTE
If the right timing belt cover is to be removed, there are O-rings
located behind it for the water pump passages.
Camshaft sprocket from the camshaft
Intake manifold assembly using the recommended procedure
Rear timing belt cover-to-cylinder head
fasteners
Cylinder head mounting bolts in the reverse order of the
tightening sequence
Cylinder head
Fig. Remove the rear timing belt cover-to-cylinder head bolts,
noting the bolt locations-3.5L engines
Fig. Right side belt cover, water pump and O-rings-3.5L engines
To install:
Fig. Cylinder head bolt tightening sequence-3.5L engines
Thoroughly clean and dry the mating surfaces of the head and
block.
WARNING
When cleaning the cylinder head and block mating surfaces, do not
use a metal scraper because the soft aluminum surfaces could be cut or
damaged. Instead, use a scraper made of wood or plastic.
Check the cylinder head for cracks, damage or engine coolant
leakage. Check the head for flatness. End-to-end, the head should be
within 0.002 in. (0.051mm) normally with 0.008 in. (0.203mm) the maximum
allowed out of true. The resurface limit is 0.008 in. (0.203mm)
maximum, the combined total dimension of stock removal from the cylinder
head, if any, and block top surface.
Place a new head gasket on the cylinder block locating dowels,
being sure the gasket is on the correct side.
Fig. Correct positioning for the head gaskets-3.5L engines
continue...
continue...
Inspect the cylinder head bolts for necking (stretching) by
holding a straightedge against the threads of each bolt. If all of the
threads are not contacting the scale, the bolt should be replaced.
WARNING
Due to the cylinder head bolt torque method used, it is imperative
that the threads of the bolts be inspected for necking prior to
installation. If the threads are necked down, the bolt should be
replaced. Failure to do so may result in parts failure or damage. New
bolts are always recommended.
Install the cylinder head into position on the engine block and
over the dowels. Install the cylinder head bolts, lubricating the
threads with clean engine oil prior to installation.
Torque the cylinder head bolts using the proper sequence as
follows:
Step 1: torque in sequence to 45 ft. lbs. (61 Nm).
Step 2: torque in sequence to 65 ft. lbs. (88 Nm).
Step 3: torque in sequence to 65 ft. lbs. (88 Nm).
Step 4: torque in sequence an additional
1
/
4
turn by using a torque angle meter.
NOTE
Inspect the bolt torque after tightening. The torque should be
over 90 ft. lbs. (122 Nm). If not, replace the cylinder head bolt.
Install the rear timing belt cover bolts and torque as follows:
M6 bolts: 105 inch lbs. (12 Nm).
M8 bolts: 21 ft. lbs. (28 Nm).
M10 bolts: 40 ft. lbs. (54 Nm).
Install the intake manifold assembly and torque the bolts
following the proper sequence to 21 ft. lbs. (28 Nm).
NOTE
The following procedure can only be used when the camshaft
sprockets have been loosened or removed from the shafts.
When the camshaft sprockets are loosened or removed, the camshafts
must be timed to the engine. Install the Camshaft Alignment tools
6642-A, to the rear of the cylinder heads.
Install both camshaft sprockets to the appropriate shafts. The
left camshaft sprocket has the Distributorless Ignition System (DIS)
pickup as part of the sprocket.
Apply thread locking compound to the threads of the camshaft
sprocket retainer bolts and install to the appropriate shafts. The right
bolt is 8.380 in. (21.3cm) long, while the left bolt is 10.0 in.
(25.4cm) long. These bolts are not interchangeable. Do not tighten the
bolts at this time. The camshaft marks should be positioned between the
marks on the cover.
Place the crankshaft sprocket to the Top Dead Center (TDC) mark on
the oil pump housing. Install the timing belt starting at the
crankshaft sprocket and working in a counterclockwise direction.
After the belt is installed around the last sprocket keep tension
on the belt until it is past the tensioner pulley.
Holding the tensioner pulley against the belt, install the
tensioner housing and torque to 21 ft. lbs. (28 Nm).
When the tensioner is in place pull the retainer pin to allow the
tensioner to extend to the pulley bracket.
Hold the right camshaft sprocket hex with a 36mm box wrench and
torque the right camshaft sprocket bolt to 75 ft. lbs. (102 Nm). Turn
the sprocket bolt an additional 90 degrees.
Hold the left camshaft sprocket hex with a 36mm box wrench and
torque the left camshaft sprocket bolt to 85 ft. lbs. (115 Nm). Turn the
sprocket bolt an additional 90 degrees.
Install or connect the following:
Camshaft alignment tools from the back of the cylinder heads
Cam covers and new O-rings. Torque the
fasteners to 20 ft. lbs.
(27 Nm). Repeat this procedure on the other camshaft.
Timing belt covers and crankshaft damper and
torque the crankshaft
damper bolt to 85 ft. lbs. (115 Nm)
Valve covers and torque the bolts to 105
inch lbs. (12 Nm)
Spark plug tube nut and O-ring and torque to
60 inch lbs. (7 Nm)
Spark plug and torque to 20 ft. lbs. (28 Nm)
A/C compressor and torque the mounting
bracket bolts to 30 ft.
lbs. (41 Nm)
Spark plug wires
Accessory drive belts and adjust to the
proper tension
Intake manifold plenum using the recommended
procedure
Air cleaner assembly
Radiator and cooling fan assemblies
Negative battery cable
Check to be sure that all hoses, wiring connectors, cables, fluid
and vacuum lines are reconnected.
Change the engine oil and oil filter.
Fill and bleed the cooling system.
Run the vehicle with the radiator cap off so coolant can be added
as required until the thermostat opens. Watch for leaks and for unusual
engine noises. Refill the radiator completely as required.
Once the vehicle has cooled, recheck the coolant and oil level.
Hope help with this (remember rated this).
×
To install:
4,232 views
Usually answered in minutes!
×