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Installation - Cylinder Head

Fig 1: Checking Cylinder Head Bolts for Stretching (Necking)
GC0003797Courtesy of DAIMLERCHRYSLER CORP.
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
NOTE: The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced. See Fig 1.

Necking (1) can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) , the bolt should be replaced.

Fig 2: Cylinder Head Gasket Positioning
GC0021188Courtesy of DAIMLERCHRYSLER CORP.
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
NOTE: Cylinder head should be cleaned and inspected prior to replacment.
  1. Position the new cylinder head gasket on engine block with the part number (1) facing up. See Fig 2. Ensure gasket is seated over the locating dowels in block.
  2. Position cylinder head onto engine block.
  3. Before installing the bolts, the threads should be lightly coated with engine oil.
    Fig 3: Cylinder Head Tightening Sequence
    GC0021185Courtesy of DAIMLERCHRYSLER CORP.
  4. Tighten the cylinder head bolts in the sequence shown. See Fig 3. Using the 4 step torque-turn method, tighten according to the following values:
    1. First: All to 34 N.m (25 ft. lbs.)
    2. Second: All to 82 N.m (60 ft. lbs.)
    3. Third: All to 82 N.m (60 ft. lbs.)
      CAUTION: Do not use a torque wrench for the Fourth step.
    4. Fourth: Turn all bolts an additional 1/4 Turn 
    Fig 4: Camshafts
    GC0042772Courtesy of DAIMLERCHRYSLER CORP.
    1 - CAMSHAFT BEARING CAPS
    2 - PLUG
    3 - CAMSHAFT
    4 - CYLINDER HEAD
    5 - CAMSHAFT OIL SEAL
  5. Install rocker arms
  6. Install camshafts (3), (Refer to ENGINE/CYLINDER HEAD/CAMSHAFT(S) - INSTALLATION) .
    Fig 5: Cylinder Head Cover Tightening Sequence (Typical Cover Shown)
    GC0021574Courtesy of DAIMLERCHRYSLER CORP.
  7. Install cylinder head cover, (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLATION) .
    Fig 6: Rear Timing Belt Cover Fasteners
    GC0042775Courtesy of DAIMLERCHRYSLER CORP.
    1 - M6 BOLTS - 12 N.m (105 in. lbs.)
    2 - M8 BOLTS - 28 N.m (250 in. lbs.)
    3 - TIMING BELT TENSIONER
  8. Install rear timing belt cover and tighten fasteners (1,2), (Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION) .
  9. Install timing belt tensioner.
  10. Install camshaft sprockets and timing belt, (Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION) .
    Fig 7: Camshaft Position Sensor -2.0/2.4L DOHC
    GC0021183Courtesy of DAIMLERCHRYSLER CORP.
    1 - PCV VALVE
    2 - EGR VALVE
    3 - CAMSHAFT POSITION SENSOR
  11. Connect cam sensor wiring connector (3).
  12. Install ignition coil and plug wires. Connect ignition coil wiring connector.
    Fig 8: Power Steering Fluid Reservoir and Bracket
    GC0021184Courtesy of DAIMLERCHRYSLER CORP.
    1 - POWER STEERING RESERVOIR
    2 - BOLT
    3 - BRACKET
  13. Non-Turbo equipped vehicles:   Install power steering pump bracket (3) and reservoir ( 1) to cylinder head.
    Fig 9: Turbocharger Lines and Hoses
    GC0019349Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL SUPPLY LINE
    2 - COOLANT RETURN LINE
    3 - COOLANT SUPPLY LINE
    4 - OIL RETURN TUBE
  14. Turbocharger equipped vehicles:  (Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/LINES AND HOSES - INSTALLATION) . See Fig 9.
    1. Install coolant return line (2).
    2. Install coolant supply line (3).
    3. Install oil supply line (1).
    4. Install oil return tube (4).
    Fig 10: Turbocharger Brackets And Heat Shields
    GC0019350Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER/LOWER HEAT SHIELDS
    2 - TURBOCHARGER SUPPORT BRACKET
    3 - ELBOW
    4 - ELBOW SUPPORT BRACKET
  15. Turbocharger equipped vehicles:  
    1. Install elbow (3)
    2. Install turbocharger support bracket (2).
    3. Install elbow support bracket (4).
    4. Install turbocharger heat shields (1).
  16. Install exhaust pipe to manifold. Tighten fasteners to 28 N.m (20 ft. lbs.).
  17. Install accessory drive belts (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) .
    Fig 11: FUEL RAIL CONNECTION
    GC0042777Courtesy of DAIMLERCHRYSLER CORP.
    1 - Fuel Rail Supply
    2 - Coolant Outlet
    3 - Radiator Pressure Cap
  18. Connect engine coolant temperature sensor connector.
  19. Connect upper radiator hose to coolant outlet (2). Connect heater hoses to thermostat housing.
  20. Install heater tube support bracket to cylinder head.
    Fig 12: Lower Intake Manifold Support Bracket - 2.4L Turbo
    GC0021186Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER INTAKE MANIFOLD
    2 - LOWER INTAKE MANIFOLD
    3 - SUPPORT BRACKET
    4 - DIPSTICK TUBE SCREW
  21. Turbocharger equipped vehicles:   Install lower intake manifold support bracket (3). See Fig 12.
    Fig 13: Dipstick Tube
    GC0021182Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIPSTICK TUBE
    2 - COOLANT TEMPERATURE SENSOR
    3 - SCREW
  22. Install fastener (3) attaching dipstick tube (1) to lower intake manifold. See Fig 13.
    Fig 14: FUEL RAIL CONNECTION
    GC0042777Courtesy of DAIMLERCHRYSLER CORP.
    1 - Fuel Rail Supply
    2 - Coolant Outlet
    3 - Radiator Pressure Cap
  23. Connect fuel supply line (1) quick-connect at the fuel rail assembly (Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) .
  24. Install upper intake manifold (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION) .
  25. Remove radiator pressure cap (3) and fill the cooling system, (Refer to FILLING COOLING SYSTEM - 2.0L/2.4L ENGINE ).
  26. Connect negative cable to battery.
    Fig 15: Air Inlet System - 2.4L Turbo
    GC0042778Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLEAN AIR HOSE
    2 - AIR CLEANER HOUSING
    3 - FRESH AIR INLET DUCT
    4 - PDC MOUNTING BRACKET
  27. Install clean air hose (1) and air cleaner housing (2), (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION) .
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