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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 >> Right Cylinder Head

Right 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.

GC0144457Courtesy of CHRYSLER GROUP, LLC
  1. If removed, install the ignition coil capacitor (1) with a M6 bolt (2) tightened to the proper 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.

    NOTE:

    Typical cylinder head bolt shown.

  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.
    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.

  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.

  5. Position the new cylinder head gasket (1) on the locating dowels (2).
    Fig 1: Cylinder Head Bolts Tightening Sequence
    GC0144194Courtesy of CHRYSLER GROUP, LLC
  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.
  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:
    NOTE:

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

    • 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. 
    GC0173564Courtesy of CHRYSLER GROUP, LLC
  9. Connect the oil temperature sensor wire harness connector (1).
  10. Install the support bracket for both cylinder heads and securely tighten the support bracket bolts.
  11. Install the electric vacuum pump. Refer to PUMP, ELECTRIC VACUUM, INSTALLATION .
    NOTE:

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

  12. Install the hydraulic lifters and rocker arms in their original location.
  13. Install the and 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
  14. Verify that the camshafts are set at TDC by positioning the alignment holes (1) vertically.
    GC0144139Courtesy of CHRYSLER GROUP, LLC
  15. Install the RH cam chain guide (1) with three bolts (2). Tighten the T30 bolts (2) to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  16. Install the RH cam chain tensioner (3) to the engine block with two bolts (4). Tighten the T30 bolts (4) to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  17. Reset the RH cam chain tensioner (3) by pushing back the tensioner piston and installing Tensioner Pin (5).

    (Special tool #8514A, Pins, Tensioner)

  18. Install the RH tensioner arm (6).
    GC0144163Courtesy of CHRYSLER GROUP, LLC
  19. Press the RH exhaust cam phaser onto the exhaust 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.

  20. Drape the right side cam chain over the RH exhaust cam phaser and onto the idler sprocket (1) so that the dimple (2) is aligned with the plated link (3) on the cam chain.
    GC0144136Courtesy of CHRYSLER GROUP, LLC
  21. 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 right side cam phasers so that the arrows (3) point away from each other and the scribe lines (4) are parallel to the valve cover sealing surface (6). Press the intake cam phaser onto the intake 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.

  22. Install the RH Camshaft Phaser Lock (5) and tighten the oil control valves (2) and (7) to the proper specifications.

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

    Refer to TORQUE SPECIFICATIONS .

    GC0144142Courtesy of CHRYSLER GROUP, LLC
  23. Remove the RH Camshaft Phaser Lock.

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

  24. Remove the Tensioner Pin (6) from the RH cam chain tensioner.

    (Special tool #8514A, Pins, Tensioner)

  25. 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).
  26. 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
  27. There should be 12 chain pins (2) between the exhaust cam phaser triangle marking (1) and the intake cam phaser circle marking (3).
  28. If the engine timing is not correct, repeat this procedure.
  29. Install the engine timing cover. Refer to COVER(S), ENGINE TIMING, INSTALLATION .
  30. Install the spark plugs. Refer to SPARK PLUG, INSTALLATION .
    GC0147024Courtesy of CHRYSLER GROUP, LLC
  31. Install the upper intake manifold support bracket (2) with the stud bolt (3) hand tight.
  32. Engage the wire harness retainer (3) from the intake manifold support bracket.
  33. Connect the ignition coil capacitor wire harness connector.
  34. Install the catalytic converter. Refer to CONVERTER, CATALYTIC, INSTALLATION .
    GC0147003Courtesy of CHRYSLER GROUP, LLC
  35. Install the serpentine belt (7). Refer to BELT, SERPENTINE, INSTALLATION .
  36. Connect the bank 1/2 variable lift solenoid wire harness connector.
  37. Install the lower intake manifolds and insulator. Refer to MANIFOLD, INTAKE, INSTALLATION .
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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