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Cylinder Head: Installation: Installation

WARNING: This page is about a different car, the 2015 Fiat 500. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Tensioner Mounting Stud
GC0152671Courtesy of CHRYSLER GROUP, LLC
  1. If removed, install the tensioner mounting stud to the cylinder head and tighten to 11 N.m (97 in. lbs.).
  2. If removed, install new exhaust maniverter mounting studs.
    Fig 2: Thermostat Housing Assembly, Engine Coolant Temperature Sensor & Fasteners
    GC0152362Courtesy of CHRYSLER GROUP, LLC
  3. If removed, install the thermostat housing and gasket with bolts (2) tightened to 10 N.m (89 in. lbs.).
    Fig 3: Checking Cylinder Head Bolts For Stretching (Necking)
    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.

  4. 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.
    Fig 4: Cylinder Head Gasket & Locating Dowels
    GC0152672Courtesy 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. Clean and prepare the gasket sealing surfaces of the cylinder head and block. Refer to ENGINE GASKET SURFACE PREPARATION .
  6. Install two cylinder head locating dowels (2).
  7. Position the new cylinder head gasket (1) on the locating dowels (2).
    Fig 5: Cylinder Head Bolt Tightening Sequence
    GC0152460Courtesy of CHRYSLER GROUP, LLC
  8. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
  9. Install the ten head bolts finger tight.
  10. Tighten the cylinder head bolts in the sequence shown in illustration, following this 4 step torque plus angle method. Tighten according to the following torque values:
    • Step 1: All to 20 N.m (15 ft. lbs.).
    • Step 2: All to 30 N.m (22 ft. lbs.).
    • Step 3: All + 90° Turn Do not use a torque wrench for this step. 
    • Step 4: All an additional + 90° Turn Do not use a torque wrench for this step. 
    Fig 6: Heater Core Inlet Hose, Engine Coolant Temperature (ECT) Sensor Electrical Connector & Cylinder Head Coolant Outlet Flange
    GC0152361Courtesy of CHRYSLER GROUP, LLC
  11. Connect the heater core inlet hose (1).
  12. Connect and lock the engine coolant temperature (ECT) sensor electrical connector (2).
    Fig 7: Oil Filter Housing Coolant Return Hose O-Ring
    GC0152673Courtesy of CHRYSLER GROUP, LLC
  13. Apply engine oil to the oil filter housing coolant return hose O-ring (1).
    Fig 8: Thermostat Housing, Pressurized Coolant Bottle Return Hose, Clamp & Bolt
    GC0152360Courtesy of CHRYSLER GROUP, LLC
  14. Install the oil filter housing coolant return hose to the thermostat housing (1). Tighten the bolt (4) to 9 N.m (80 in. lbs.).
    CAUTION:

    The vacuum hose and the pressurized coolant bottle return hose have the same quick-connect fitting end. Verify that the hoses are correctly installed. Failure to properly install the hoses can result in engine damage.

  15. Connect the pressurized coolant bottle return hose (2).
  16. Connect the lower radiator hose and tighten the clamp (3).
    Fig 9: Side Timing Belt Cover & Bolt
    GC0152659Courtesy of CHRYSLER GROUP, LLC
  17. Install the side timing belt cover (1) with bolt (2) tightened to 25 N.m (18 ft. lbs.).
    Fig 10: Upstream And Downstream Oxygen Sensors, Maniverter & Fasteners
    GC0152389Courtesy of CHRYSLER GROUP, LLC
  18. Install the maniverter (4), cooling module and front fascia. Refer to MANIFOLD, EXHAUST, INSTALLATION .
    Fig 11: PCM, Retainers, Ground Strap & Nuts
    GC0152394Courtesy of CHRYSLER GROUP, LLC
  19. Lower the vehicle.
  20. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).
    Fig 12: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  21. Install the battery tray (3) with one nut (5) and two bolts (1) tightened to 25 N.m (18 ft. lbs.).
  22. Engage the engine wire harness connector (2) to the battery tray (3).
  23. Engage two engine wire harness retainers (4) to the battery tray (3).
  24. Engage two starter wire harness retainers (6) to the battery tray (3).
    Fig 13: PCM Electrical Connectors
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  25. Connect the powertrain control module (PCM) electrical connectors (1 and 2).
    Fig 14: Camshaft Bearing Housing Bolt Tightening Sequence
    GC0152667Courtesy of CHRYSLER GROUP, LLC
  26. Install the camshaft bearing housing. Refer to HOUSING, CAMSHAFT BEARING, INSTALLATION .
    Fig 15: Engine Cover
    GC0152354Courtesy of CHRYSLER GROUP, LLC
  27. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to STANDARD PROCEDURE  .
  28. Fill the cooling system. Refer to STANDARD PROCEDURE .
  29. Install the engine cover (1).
  30. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  31. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
    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. Refer to appropriate Engine Electrical Diagnostics article.

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