LEMON Manuals: Even more car manuals for everyone
Home >> Chrysler >> 2011 >> 300 C, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 22 (6.7L Engine (Service Information)) >> Cylinder Head >> Installation >> Installation

Cylinder Head: Installation: Installation

WARNING: This page is about a different car, the 2011 RAM Pickup and 2011 RAM Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Cylinder Head Bolt Torque Sequence
GC0108502Courtesy of CHRYSLER LLC
WARNING:

THE OUTSIDE EDGE OF THE HEAD GASKET IS VERY SHARP. WHEN HANDLING THE NEW HEAD GASKET, USE CARE NOT TO INJURE YOURSELF.

  1. Install a new gasket with the part number side up, and locate the gasket over the dowel sleeves.
  2. Using an engine lifting crane, lower the cylinder head onto the engine.
  3. Lightly lubricate head bolts under bolt head and on threads, with engine oil and install. Using the sequence shown in illustration, tighten bolts in the following steps:
    1. Tighten bolts to 70 N.m (52 ft. lbs.).
    2. Back off 360° in sequence.
    3. Tighten bolts to 105 N.m (77 ft. lbs.).
    4. Recheck all bolts to 105 N.m (77 ft. lbs.).
    5. Tighten all bolts an additional 1/4 turn (90°).
    Fig 2: Push Rod Removal/Installation
    GC0108503Courtesy of CHRYSLER LLC
  4. Install push rods into their original locations. Verify that they are seated in the tappets  .
  5. Inspect rocker housing gasket for cuts and proper installation into groove. Replace if damaged.
  6. Install rocker housing. Tighten bolts to 24 N.m (18 ft. lbs.).
  7. Install fuel injector. Refer to INJECTOR(S), Fuel, Installation .
    Fig 3: Identifying Rocker Arm & Pedestal
    GC0108504Courtesy of CHRYSLER LLC
    1 - ROCKER ARM
    2 - PEDESTAL
  8. Lubricate valve stem tips and install the crossheads in their original locations.
  9. Lubricate the rocker arms (1) and pedestals (2) and install them in their original locations. Install the bolts and tighten them to 36 N.m (27 ft. lbs.).
  10. Verify that the valve lash settings are maintained at 0.254 mm (0.010 in) for the intake valve and 0.660 mm (0.026 in) for the exhaust valve. Refer to Standard Procedure .
    Fig 4: Cylinder Head And Gasket
    GC0108488Courtesy of CHRYSLER LLC
  11. Install cylinder head cover gasket onto rocker housing.
  12. Install injector harness nuts. Tighten to 1.25 N.m (11 in. lbs.).
  13. Connect injector harness connectors at cylinder head cover gasket.
  14. Install P-clip to cylinder head and tighten to 24 N.m (18 ft. lbs.).
  15. Connect the IAT/MAP sensor connector.
    Fig 5: Fuel Lines At Rail
    GC0108493Courtesy of CHRYSLER LLC
    CAUTION:

    Failure to follow procedure will result in fuel leaks and/or fuel system failure.

  16. Install the fuel rail and high pressure fuel lines as follows: 
    1. Hand tighten fuel rail bolts.
    2. Hand tighten fuel drain line to pressure limiting valve.
    3. Hand tighten fuel rail-to-cylinder head high pressure fuel lines.
    4. Hand tighten fuel pump to fuel rail line.
    5. Tighten fuel line nuts at cylinder head to 40 N.m (30 ft. lbs.).
    6. Tighten fuel line nuts at fuel rail to 40 N.m (30 ft. lbs.)
    7. Using a back up wrench, tighten fuel pump to fuel rail line to 40 N.m (30 ft. lbs.). At injection pump.
    8. Tighten fuel pump to fuel rail line to 40 N.m (30 ft. lbs.) at fuel rail.
    9. Tighten banjo bolt at pressure limiting valve and fuel rail to 24 N.m (18 ft. lbs.).
    10. Tighten rail bolts to 24 N.m (18 ft. lbs.).
    11. Connect fuel pressure sensor.
  17. Reposition No. 6 fuel line shield and tighten to 43 N.m (32 ft. lbs.).
  18. Install the fuel filter to injection pump low pressure line. Inspect and replace sealing washers if necessary.
  19. Connect fuel return line at back of cylinder head hand tight.
  20. Tighten banjo connections at cylinder head to 24 N.m (18 ft. lbs.).
  21. Using new gaskets, install the air inlet housing. Tighten bolts to 24 N.m (18 ft. lbs.).
  22. Install wire harness P-clip and push on clip to air inlet housing.
  23. Connect engine oil level indicator tube at fuel filter housing and at air inlet housing.
  24. Install the charge air cooler-to-air inlet housing duct assembly. Tighten all clamps to 11 N.m (97 in. lbs.).
    Fig 6: Intake Air Heater Assembly
    GC0108492Courtesy of CHRYSLER LLC
  25. Connect intake grid heater wire.
  26. Secure engine harness to front of cylinder head with bolt at four locations.
  27. Connect engine coolant temperature sensor connector.
  28. Connect radiator upper hose to thermostat housing.
    Fig 7: Diesel Generator
    GC0108131Courtesy of CHRYSLER LLC
    1 - GENERATOR
    2 - MOUNTING BOLTS
  29. Rotate generator into position. Install upper bolt and tighten upper and lower bolts.
  30. Install wire harness push-on clip below bracket.
  31. Install wire harness P-clip to top of bracket.
  32. Install fan support and tighten to 32 N.m (24 ft. lbs.).
  33. Install cooling fan/drive. Refer to FAN, Cooling, Electric, Installation .
  34. Install accessory drive belt. Refer to BELT, Serpentine, Installation .
    Fig 8: Cylinder Head And Exhaust Manifold
    GC0108490Courtesy of CHRYSLER LLC
    1 - Retention Strap
    2 - Manifold
    3 - Gasket
    4 - Manifold
    5 - Manifold Heat Shield
  35. Install exhaust manifold/turbocharger assembly, using new gaskets. Start all bolts/spacers by hand. Starting from the center bolts out, Tighten bolts to 43 N.m (32 ft. lbs.), then retighten from the center out again.
  36. Install exhaust manifold heat shield to exhaust manifold studs. Install retaining nuts. Tighten to 24 N.m (18 ft. lbs.).
  37. Install exhaust bolt retention straps across cylinders No. 5 and No. 6.
  38. Using a new gasket, connect the turbocharger oil drain tube. Tighten to 24 N.m (18 ft. lbs.).
    Fig 9: RH Insulator
    GC0108489Courtesy of CHRYSLER LLC
    1 - Mount
    2 - Insulator
    3 - Bolt
  39. Install the right motor mount. Refer to INSULATOR, Engine Mount, Front, Installation, 6.7L  or INSULATOR, Engine Mount, Rear, Installation, 6.7L .
    Fig 10: Charge Air Cooler
    GC0108505Courtesy of CHRYSLER LLC
    1 - INTAKE MANIFOLD
    2 - CHARGE AIR COOLER TUBE
    3 - CHARGE AIR COOLER
    4 - TURBOCHARGER FRESH AIR INTAKE
    5 - TURBOCHARGER
  40. Perform the turbocharger pre-lube procedure. Refer to TURBOCHARGER, Installation, 6.7L .
  41. Connect the turbocharger oil supply line. Tighten to 24 N.m (18 ft. lbs.).
  42. Connect the turbocharger coolant lines. Tighten the banjo bolts to 24 N.m (18 ft. lbs.)
  43. Install the EGR cooler and associated hardware. Refer to COOLER, EGR, Installation .
  44. Install air cleaner housing and duct.
  45. Connect air inlet temperature/pressure sensor.
  46. Raise vehicle on hoist.
    NOTE:

    Do not reuse the clamp for the exhaust pipe to turbocharger elbow connection.

  47. Install the exhaust pipe to turbocharger elbow using a new clamp. Tighten bolts to 10 N.m (89 in. lbs.).
    Fig 11: Removing/installing Battery & Components
    GC0083462Courtesy of CHRYSLER LLC
  48. Lower vehicle.
  49. Connect both negative battery cables.
  50. Fill engine coolant. Refer to Standard Procedure .
  51. Start engine and check for leaks.
scientia non olet · About LEMON Manuals