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Cylinder Head: Installation

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Head Gasket Installation
GC0003963Courtesy of DAIMLERCHRYSLER CORP.
1 - HEAD GASKET
2 - OIL HOLES
  1. Clean all surfaces of cylinder block and cylinder heads.
  2. Clean cylinder block front and rear gasket surfaces using a suitable solvent.
    CAUTION: The head gaskets (1) are interchangeable between left and right sides. They are marked "UP" to indicate direction to face up.
    CAUTION: Rotate crankshaft at 45 degrees, so that all pistons are 1/2 the way down the cylinder bore to avoid piston to valve contact.
    Fig 2: 5.7L/6.1L Cylinder Head Components
    GC0038689Courtesy of DAIMLERCHRYSLER CORP.
    1 - CYLINDER HEAD COVER
    2 - GASKET
    3 - FASTENERS
    4 - CYLINDER HEAD
    5 - HEAD GASKET
  3. Position new cylinder head gaskets (5) onto the cylinder block.
  4. Position cylinder heads (4) onto head gaskets (5) and cylinder block.
    Fig 3: Cylinder Head Bolt Tightening Sequence
    GC0003962Courtesy of DAIMLERCHRYSLER CORP.
  5. Tighten the cylinder head bolts in three steps using the sequence provided :
    1. Step 1- Snug tighten M12 cylinder head bolts, in sequence, to 34 N.m (25 ft. lbs.) and M8 bolts to 20 N.m (15 ft. lbs.) torque.
    2. Step 2- Tighten M12 cylinder head bolts, in sequence, to 54 N.m (40 ft. lbs.) and verify M8 bolts to 20 N.m (15 ft. lbs.) torque.
    3. Step 3- Turn M12 cylinder head bolts, in sequence, 90 degrees and tighten M8 bolts to 34 N.m (25 ft. lbs.) torque.
    Fig 4: Pushrod Retaining Plate
    GC0003954Courtesy of DAIMLERCHRYSLER CORP.
    1 - PUSHROD RETAINING PLATE FASTENER
    2 - PUSHROD HOLDER
  6. Install push rods and rocker arm assemblies in their original position, using pushrod retaining plate (1) special tool# 9070. (Refer to ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - INSTALLATION) .
  7. Install the intake manifold and throttle body assembly (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION) .
  8. If required, adjust spark plugs to specifications. Install the plugs.
  9. Connect the heater hoses.
  10. Install the fuel supply line.
  11. Install the power steering pump.
  12. Install the drive belt. Refer to ACCESSORY DRIVE .
    Fig 5: 5.7L/6.1L Cylinder Head Components
    GC0038689Courtesy of DAIMLERCHRYSLER CORP.
    1 - CYLINDER HEAD COVER
    2 - GASKET
    3 - FASTENERS
    4 - CYLINDER HEAD
    5 - HEAD GASKET
    Fig 6: Cylinder Head Cover Torque Sequence
    GC0038690Courtesy of DAIMLERCHRYSLER CORP.
  13. Install cylinder head covers (1). (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) .
  14. Install ignition coils.
  15. Reconnect ignition coil wiring. See Figure.
  16. Connect the evaporation control system.
  17. Install the air cleaner. Refer to INSTALLATION .
  18. Fill cooling system. (Refer to COOLING - STANDARD PROCEDURE) .
  19. Connect the negative cable to the battery.
  20. Start engine check for leaks.
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