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Cylinder Head: Installation

WARNING: This page is about a different car, the 2003 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean all surfaces of cylinder block and cylinder heads.
  2. Clean cylinder block front and rear gasket surfaces using a suitable solvent.
  3. Position new cylinder head gaskets onto the cylinder block.
  4. Position cylinder heads onto head gaskets and cylinder block.
  5. Starting at top center, tighten all cylinder head bolts, in sequence (Fig 1).
    CAUTION: When tightening the rocker arm bolts, make sure the piston in that cylinder is NOT at TDC. Contact between the valves and piston could occur.
    Fig 1: Identifying Cylinder Head Bolt Tightening Sequence
    G02657138Courtesy of DAIMLERCHRYSLER CORP.
  6. Install push rods and rocker arm assemblies in their original position. Tighten the bolts to 28 N.m (21 ft. lbs.) torque.
  7. Install the intake manifold (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD-INSTALLATION ) and throttle body assembly.
  8. Install exhaust manifolds (Refer to ENGINE/MANIFOLDS/EXHAUST MANIFOLD-INSTALLATION ).
  9. If required, adjust spark plugs to specifications. Install the plugs and tighten to 41 N.m (30 ft. lbs.) torque.
  10. Install coil wire.
  11. Connect heat indicator sending unit wire.
  12. Connect the heater hoses and bypass hose.
  13. Install distributor cap and wires.
  14. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
  15. Install the fuel supply line (Refer to FUEL LINE DISCONNECT FITTINGS ).
  16. Install the generator and drive belt (Refer to DRIVE BELTS ). Tighten generator mounting bolt to 41 N.m (30 ft. lbs.) torque. Tighten the adjusting strap bolt to 23 N.m (200 in. lbs.) torque.
  17. Install the intake manifold-to-generator bracket support rod. Tighten the bolts.
  18. Place the cylinder head cover gaskets in position and install cylinder head covers (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S)-INSTALLATION ).
  19. Install closed crankcase ventilation system.
  20. Connect the evaporation control system.
  21. Install the air cleaner.
  22. Fill cooling system (Refer to STANDARD PROCEDURE--REFILLING COOLING SYSTEM 3.9L/5.9L ).
  23. Connect the negative cable to the battery.
  24. Start engine check for leaks.
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