Installation - Cylinder Head

Fig 1: Checking Bolts for Stretching (Necking)

Courtesy of DAIMLERCHRYSLER CORP.

Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt(s) should be replaced.

Fig 2: Cylinder Head and Gasket

Courtesy of DAIMLERCHRYSLER CORP.

1. Clean the cylinder head (3) and cylinder block sealing surfaces (Refer to ENGINE/CYLINDER HEAD - CLEANING)  .
2. Position a new cylinder head gasket (2) on the locating dowels.
3. Position the cylinder head onto the engine block. Make sure the cylinder head seats fully over the locating dowels.
   CAUTION: Avoid damaging spark plug tubes when installing/torquing cylinder head bolts.
4. Before installing cylinder head bolts, the threads should be oiled with engine oil.
   Fig 3: Cylinder Head Bolt Tightening Sequence

   Courtesy of DAIMLERCHRYSLER CORP.
5. Tighten the cylinder head bolts in the sequence shown. Using the 4 step torque method, tighten according to the following values:

   Step One:

   1. Tighten the ten M10 bolts to 20 N.m (15 ft. lbs.)
   2. Tighten the two M8 bolts to 15 N.m (11 ft. lbs.)

   Step Two:

   1. Tighten the ten M10 bolts to 41 N.m (30 ft. lbs.)

   Step Three:

   1. Recheck the ten M10 bolts to 41 N.m (30 ft. lbs.)

   Step Four:

   1. Do not use a torque wrench for this step.   Tighten the ten M10 bolts an additional 90 degrees
   2. Tighten the two M8 bolts to 30 N.m (22 ft. lbs.)
   Fig 4: Timing Chain Guide Mounting

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - RIGHT TIMING CHAIN GUIDE (MOVABLE)

   2 - LEFT TIMING CHAIN GUIDE (FIXED)

   3 - FASTENER(S)

   4 - CYLINDER HEAD PLUG(S)

6. Install timing chain guides (1,4). Torque fasteners (2) to 28 N.m (250 in. lbs.).
7. Retrieve timing chain from crankcase with a magnet or fabricated hook.
   Fig 5: Identify Timing Chain Link for Reassembly Purposes

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - PAINT THE LINK THAT ALIGNS WITH TIMING MARK

   2 - CAMSHAFT SPROCKET TIMING MARK

8. Align triangular timing mark on cam sprocket (2) with the timing chain link that was painted (1) during disassembly. Install timing chain on cam sprocket.
9. Install camshaft sprocket on the camshaft.
   Fig 6: Special Tool 8435 - Camshaft Sprocket Holding Wrench

   Courtesy of DAIMLERCHRYSLER CORP.
   CAUTION: Do Not use an impact wrench for tightening the camshaft sprocket bolt. Damage to the camshaft timing pin can result. Use a hand wrench only.
10. Install camshaft sprocket bolt. While holding the camshaft sprocket with Special Tool 8435 (1), torque bolt to 115 N.m (85 ft. lbs.).
    Fig 7: Timing Chain Tensioner/Oil Reservoir Cap/Plug

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - CHECK BALL

    2 - PLUG WITH SEAL RING

    3 - OIL RESERVOIR CAP

    4 - TIMING CHAIN TENSIONER

11. Reset the timing chain tensioner by removing the oil reservoir cap (3) from timing chain tensioner (4).
    Fig 8: Resetting Timing Chain Tensioner

    Courtesy of DAIMLERCHRYSLER CORP.
12. Place the timing chain tensioner on a clean flat surface.
13. Place your palm against the tensioner and press down on the tensioner with continuous pressure until the fully extended tensioner bottoms out.
    Fig 9: Timing Chain Tensioner/Oil Reservoir Cap/Plug

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - CHECK BALL

    2 - PLUG WITH SEAL RING

    3 - OIL RESERVOIR CAP

    4 - TIMING CHAIN TENSIONER

14. Install oil reservoir cap (3) onto timing chain tensioner.
    Fig 10: LOCATING TIMING CHAIN TENSIONER

    Courtesy of DAIMLERCHRYSLER CORP.
15. Install timing chain tensioner (3) with oil reservoir cap (2) into engine block.
16. Install timing chain tensioner plug with seal ring (1). Torque plug to 62 N.m (46 ft. lbs.).
    Fig 11: Timing Chain Tensioner Activation

    Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Do not pry directly on chain. Damage to timing chain may occur.
17. Using a long thin screwdriver, pry in on the right (movable) timing chain guide until the timing chain tensioner rachets out to tension the chain.
    NOTE: Ensure the timing chain is properly positioned within the channel of the timing chain guides.
    Fig 12: Timing Chain Guide Mounting

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - RIGHT TIMING CHAIN GUIDE (MOVABLE)

    2 - LEFT TIMING CHAIN GUIDE (FIXED)

    3 - FASTENER(S)

    4 - CYLINDER HEAD PLUG(S)

18. Install cylinder head plugs (3). Torque to 18 N.m (162 in. lbs.).
    Fig 13: Cylinder Head Cover

    Courtesy of DAIMLERCHRYSLER CORP.
19. Install cylinder head cover (2) (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S)  - INSTALLATION).
20. Install camshaft position sensor. Torque fastener to 10 N.m (85 in. lbs.). Reconnect connector.
    Fig 14: RIGHT SIDE - ENGINE MOUNT & BRACKETS

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - Item_1

    2 - Item _2

21. Install right engine mount bracket (Refer to ENGINE/ENGINE MOUNTING/ENGINE MOUNT BRACKET - INSTALLATION) .
22. Lower engine until right engine mount through bolt can be installed.
23. Install right engine mount through bolt (1).
24. Remove floor jack from under engine.
25. Install fastener securing power steering return line to right engine mount bracket.
26. Install fasteners securing power steering reservoir to right engine mount bracket.
27. Install upper torque strut (4).
28. Raise vehicle on hoist.
29. Install fasteners securing exhaust pipe to exhaust manifold. Torque fasteners to 28 N.m (250 in. lbs.).
30. Install lower torque strut (6).
    Fig 15: Splash Shield

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - RIGHT MOUNT BOLT ACCESS PLUG

    2 - FASCIA

    3 - SPLASH SHIELD

    4 - CRANKSHAFT BOLT ACCESS PLUG

31. Install accessory drive belt splash shield (3).
32. Install right front wheel.
33. Lower vehicle.
34. Connect upper radiator hose.
35. Install fastener securing heater return tube to thermostat housing.
36. Connect heater hoses to thermostat housing and heater return tube.
37. Connect the following electrical components:
    1. Upstream Oxygen Sensor
    2. Camshaft Position Sensor
    3. Ignition Coil and Capacitor
    4. Fuel Injectors
    5. MAP Sensor
    6. Knock Sensor
    7. Electronic Throttle Control Motor
    8. ECT Sensor
    9. Generator
38. Connect vacuum hoses to throttle body.
39. Connect ground strap to cylinder head.
    Fig 16: AIR CLEANER HOUSING

    Courtesy of DAIMLERCHRYSLER CORP.
40. Connect throttle body air inlet hose (4).
41. Connect negative battery cable.
42. Install air cleaner housing (1).
43. Fill cooling system (Refer to COOLING/ENGINE - STANDARD PROCEDURE) ).
44. Perform torque strut adjustment procedure (Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS)  .