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Installation - Cylinder Head

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Piston protrusion must be measured to determine cylinder head gasket thickness if one or more cylinder liners have been replaced (Refer to ENGINE/CYLINDER HEAD - STANDARD PROCEDURE) .
NOTE: If cylinder liner(s) have not been removed, the same thickness head gasket that was removed can be used.
  1. Clean and inspect gasket mating surfaces.
  2. Position correct head gasket on engine block.
  3. Place cylinder head on engine block.
    CAUTION: New cylinder head bolts must be used. Do Not lubricate new cylinder head bolts. They already are coated with an anti scuff treatment.
  4. Tighten cylinder head bolts following procedure below.

    Cylinder Head Bolt Torquing Procedure

      Fig 1: CYLINDER HEAD TIGHTENING
      GC0026128Courtesy of DAIMLERCHRYSLER CORP.
    1. Tighten all cylinder head bolts to 30 N.m (22 ft. lbs.) starting from the center bolts, following the cylinder head scheme and the following sequence: 3-2-1-10-9-8-7-6-5-4-11-12-13-14-15-16-17-18. See Fig 1.
    2. Without loosening any bolts, starting from the center bolts, tighten each bolt an additional 75° in the following sequence: 10-9-8-7-6-5-4-3-2-1. See Fig 1.
    3. Tighten the lateral cylinder head bolts an additional 50° in the following sequence: 11-12-13-14-15-16-17-18. See Fig 1.
    4. Finally tighten all bolts an additional 75° in the following sequence: 10-9-8-7-6-5-4-3-2-1-11-12-13-14-15-16-17-18. See Fig 1.
  5. Slide exhaust manifold and turbocharger on exhaust manifold studs. See Fig 2.
    Fig 2: THERMOSTAT HOUSING
    GC0025182Courtesy of DAIMLERCHRYSLER CORP.
    1 - THERMOSTAT HOUSING GASKET
    2 - THERMOSTAT HOUSING
    3 - TURBOCHARGER OIL SUPPLY LINE BANJO BOLT
    4 - THERMOSTAT HOUSING RETAINING BOLTS
    5 - BRASS WASHER
    6 - EXHAUST MANIFOLD GASKET
    7 - EXHAUST MANIFOLD
    8 - EXHAUST MANIFOLD HEATSHIELD
    9 - EXHAUST MANIFOLD HEATSHIELD RETAINING BOLTS
    10 - OIL RETURN HOSE
    11 - HOSE CLAMPS
    12 - EXHAUST MANIFOLD RETAINING NUTS
    13 - TURBOCHARGER DOWNPIPE STUDS
    14 - TURBOCHARGER DOWN PIPE GASKET
    15 - TURBOCHARGER DOWNPIPE
    16 - TURBOCHARGER DOWNPIPE RETAINING NUT
  6. Install exhaust manifold retaining nuts. Tighten the nuts to 36 N.m ( 27 ft. lbs) in a cross sequence beginning in the middle and working outward, then perform the tightening sequence to the exhaust manifold nuts again.
  7. Install exhaust manifold heat shield. Torque bolts to 24.5 N.m (217 in. lbs).
  8. Install turbocharger outlet to charge air cooler pipe.
  9. Install upper radiator hose.
  10. Connect glow plug and coolant temperature sensor electrical connectors.
  11. Install new cylinder head cover/intake manifold gasket.
  12. Install rocker arm and lifter assemblies.Be sure to put rocker arm and lifter assemblies in same location as removed. 
    CAUTION: Care must be taken not to knock the rocker arms off of the valves when installing the cylinder head cover/intake manifold.
  13. Install cylinder head cover/intake manifold (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION ).
  14. Install timing belt inner cover (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - INSTALLATION) .
    NOTE: Make sure the crankshaft is rotated to the 90 degree ATCD, or the 3 O'clock position (Refer to ENGINE/VALVE TIMING - STANDARD PROCEDURE) .
  15. Install both camshaft gears and tighten bolts finger tight.
  16. Install timing belt (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) .
    Fig 3: VM.1085 CAMSHAFT LOCKING TOOL
    GC0026125Courtesy of DAIMLERCHRYSLER CORP.
  17. Using VM.1085, torque cam gear retaining bolts to 108 N.m. See Fig 3.
  18. Install timing belt outer cover (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - INSTALLATION) .
  19. Remove both camshaft locking pins at this time (Refer to ENGINE/VALVE TIMING - STANDARD PROCEDURE) .
  20. Install fuel injectors (Refer to FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION) .
  21. Install brake booster line bracket to intake manifold.
  22. Install oil level indicator tube to intake manifold.
  23. Connect fuel pump high pressure line to fuel rail.
  24. Install fuel injector pressure lines.
  25. Connect fuel return hose to fuel injectors.
  26. Connect engine coolant hoses to thermostat housing.
  27. Raise vehicle.
  28. Reconnect exhaust system bracket at transmission crossmember.
  29. Connect exhaust stabilizer bracket to lower exhaust manifold. See Fig 2.
  30. Install turbocharger oil supply line to turbocharger.
  31. Lower vehicle.
  32. Install turbocharger heat shield.
  33. Install exhaust manifold heat shield.
  34. Install air cleaner housing.
  35. Install main engine wiring harness and connect all ancillary electrical components.
  36. Install viscous heater.
  37. Install vibration damper.
  38. Install generator (Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION) .
  39. Install cooling fan support (Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION) .
  40. Install front engine lift bracket.
  41. Install power steering pump pulley.
  42. Install accessory drive belt tensioner and both idler pulleys. Idler pulley retaining bolts are L. H. Thread. 
  43. Install accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) .
  44. Install cooling fan and fan drive viscous clutch assembly. Refer to RADIATOR - FAN - VISCOUS .
  45. Install upper radiator core support.
  46. Refill cooling system. Refer to STANDARD PROCEDURE .
  47. Install engine cover and bracket. Refer to ENGINE COVER .
  48. Connect negative battery cable.
  49. Start engine and allow to warm. Turn engine off and inspect for leaks. Refer to WARNINGS in FUEL SYSTEM .
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