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Home >> Dodge and Ram >> 2023 >> ProMaster 2500 >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 3.6L Engine (Service Information) (2 Of 2) >> Cylinder Head >> Installation >> Left Cylinder Head

Left Cylinder Head

GC0144190Courtesy of CHRYSLER GROUP, LLC
CAUTION:

The magnetic timing wheels must not come in contact with magnets (pickup tools, trays, etc.) or any other strong magnetic field. This will destroy the timing wheels ability to correctly relay camshaft position to the camshaft position sensor.

  1. If removed, install the ignition coil capacitor and tighten to the proper specifications.specifications. Refer to TORQUE SPECIFICATIONS .
    GC0104468Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

  2. Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
  3. Clean and prepare the gasket sealing surfaces of the cylinder head and block. Refer to ENGINE GASKET SURFACE PREPARATION .
    CAUTION:

    Non-compressible debris such as oil, coolant or RTV sealants that are not removed from bolt holes can cause the aluminum casting to crack when tightening the bolts.

  4. Clean out the cylinder head bolt holes in the engine block.
    WARNING:

    The multi-layered steel head gaskets have very sharp edges that could cause personal injury if not handled carefully.

    CAUTION:

    The installation of the cylinder head gaskets are not interchangeable between the left and right cylinder heads. They are clearly marked (3) with "R" for right and "L" for left. They must be applied on a dry surface, without the use of any adhesives.

    GC0144308Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.

  5. Position the NEW  cylinder head gasket (1) on the locating dowels (2).
  6. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
    NOTE:

    Do not apply any additional oil to the bolt threads.

  7. Install the eight head bolts finger tight.
    Fig 1: Cylinder Head Bolts Tightening Sequence
    GC0144166Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    For engine builds using a new block follow steps 1-9. For engine re-builds (reuse block) follow step 6-9.

  8. Tighten the cylinder head bolts in the sequence shown, following this 9 step torque plus angle method. The torque sequence must be used for each step. Tighten according to the following torque values:
    • Step 1: All to 30 N. m (22 ft. lbs.)
    • Step 2: All to 45 N. m (33 ft. lbs.)
    • Step 3: Re-tighten all to 45 N. m (33 ft. lbs.)
    • Step 4: All + 125° Turn (optional angle if 125° rotation cannot be accomplished in one motion; tighten all by turning 35° followed by tightening all by turning 90°) Do not use a torque wrench for this step. 
    • Step 5: Loosen all fasteners in reverse of sequence shown
    • Step 6: All to 30 N. m (22 ft. lbs.)
    • Step 7: All to 45 N. m (33 ft. lbs.)
    • Step 8: Re-tighten all to 45 N. m (33 ft. lbs.)
    • Step 9: All + 130° Turn (optional angle if 130° rotation cannot be accomplished in one motion; tighten all by turning 40° followed by tightening all by turning 90°) Do not use a torque wrench for this step. 
    NOTE:

    If the hydraulic lifters and rocker arms are being reused, reassemble them into their original locations.

  9. Install the hydraulic lifters and rocker arm assemblies.
  10. Install the camshafts. Refer to CAMSHAFT, ENGINE, INSTALLATION .
    CAUTION:

    Do not rotate the camshafts more than a few degrees independently of the crankshaft. Valve to piston contact could occur resulting in possible valve damage. If the camshafts need to be rotated more than a few degrees, first move the pistons away from the cylinder heads by rotating the crankshaft counterclockwise to a position 30° before-top-dead-center. Once the camshafts are returned to their top-dead-center position, rotate the crankshaft clockwise to return the crankshaft to top-dead-center.

    GC0144138Courtesy of CHRYSLER GROUP, LLC
  11. Rotate the camshafts CW to TDC by positioning the alignment holes (1) vertically.
    GC0144140Courtesy of CHRYSLER GROUP, LLC
  12. Install the LH cam chain guide (2) with two bolts (4). Tighten the T30 bolts (4) to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  13. Install the LH cam chain tensioner (5) to the cylinder head with two bolts (6). Tighten the T30 bolts (6) to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  14. Reset the LH cam chain tensioner (5) by lifting the pawl (3), pushing back the piston and installing Tensioner Pin (7)

    (Special tool #8514A, Pins, Tensioner)

    Refer to RESETTING LEFT CAM CHAIN TENSIONER .

  15. Install the LH tensioner arm (1).
    GC0144165Courtesy of CHRYSLER GROUP, LLC
  16. Press the LH intake cam phaser onto the intake camshaft. Install and hand tighten the oil control valve.
    CAUTION:

    Always reinstall timing chains so that they maintain the same direction of rotation. Inverting a previously run chain on a previously run sprocket will result in excessive wear to both the chain and sprocket.

  17. Drape the left side cam chain over the LH intake cam phaser and onto the idler sprocket (1) so that the arrow (3) is aligned with the plated link (2) on the cam chain.
    GC0144164Courtesy of CHRYSLER GROUP, LLC
  18. While maintaining this alignment, route the cam chain around the exhaust and intake cam phasers so that the plated links are aligned with the phaser timing marks (1). Position the left side cam phasers so that the arrows (3) point toward each other and are parallel to the valve cover sealing surface (5). Press the exhaust cam phaser onto the exhaust cam, install and hand tighten the oil control valve (2).
    NOTE:

    Minor rotation of a camshaft (a few degrees) may be required to install the camshaft phaser or phaser lock.

  19. Install the LH Camshaft Phaser Lock (4) and tighten the oil control valves (2) and (6) to the proper specifications.

    (Special tool #10202, Locks, Camshaft/Phaser)

    Refer to TORQUE SPECIFICATIONS .

    GC0144142Courtesy of CHRYSLER GROUP, LLC
  20. Remove the LH Camshaft Phaser Lock.

    (Special tool #10202, Locks, Camshaft/Phaser)

  21. Remove the Tensioner Pin (1) from the LH cam chain tensioner.

    (Special tool #8514A, Pins, Tensioner)

  22. Rotate the crankshaft CW two complete revolutions stopping when the dimple (4) on the crankshaft is aligned the with the block/bearing cap junction (5).
  23. While maintaining this alignment, verify that the arrows on the left side cam phasers (2) point toward each other and are parallel to the valve cover sealing surface (3) and that the right side cam phaser arrows (7) point away from each other and the scribe lines (9) are parallel to the valve cover sealing surface (8).
    GC0207766Courtesy of CHRYSLER GROUP, LLC
  24. There should be 12 chain pins (2) between the exhaust cam phaser triangle marking (1) and the intake cam phaser circle marking (3).
  25. If the engine timing is not correct, repeat this procedure.
  26. Install the EGR cooler. Refer to COOLER, EXHAUST GAS RECIRCULATION (EGR), INSTALLATION .
  27. Install the support bracket for both cylinder heads and securely tighten the support bracket bolts.
  28. Install the electric vacuum pump. Refer to PUMP, ELECTRIC VACUUM, INSTALLATION .
  29. Install the catalytic converter. Refer to CONVERTER, CATALYTIC, INSTALLATION .
  30. Install the engine timing cover. Refer to COVER(S), ENGINE TIMING, INSTALLATION .
  31. Install the spark plugs. Refer to SPARK PLUG, INSTALLATION .
  32. Connect the ignition coil capacitor wire harness connector.
    GC0147017Courtesy of CHRYSLER GROUP, LLC
  33. Install the generator (2). Refer to GENERATOR, INSTALLATION .
    GC0147003Courtesy of CHRYSLER GROUP, LLC
  34. Install the serpentine belt (7). Refer to BELT, SERPENTINE, INSTALLATION .
    GC0144406Courtesy of CHRYSLER GROUP, LLC
  35. Install the LH upper intake manifold support brackets (1). Loosely install the stud bolts (2).
  36. Connect the bank 2/2 variable lift solenoid wire harness connector.
  37. Install the lower intake manifolds and insulator. Refer to MANIFOLD, INTAKE, INSTALLATION .
  38. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to ENGINE OIL SERVICE .
  39. Fill the cooling system. Refer to COOLANT SYSTEM AIR EVACUATION .
  40. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  41. Connect the negative battery cable and tighten nut to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  42. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to COOLANT SYSTEM AIR EVACUATION .
NOTE:

The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

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