Installation

Fig. 29 Head Gasket Installation:

INSTALLATION
1. Clean all surfaces of cylinder block and cylinder heads.
2. Install new gaskets on cylinder block Fig. 29.

Fig. 30 Checking Bolts For Stretching (Necking):

3. The cylinder head bolts are torqued using the torque yield method, they should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced Fig. 30.
4. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced.

Fig. 31 Cylinder Head Tightening Sequence:

5. Tighten the cylinder head bolts 1 through 8 in the sequence shown in Fig. 31. Using the 4 step torque turn method, tighten according to the following values:
^ First-All to 61 Nm (45 ft. lbs.)
^ Second-All to 88 Nm (65 ft. lbs.)
^ Third-All (again) to 88 Nm (65 ft. lbs.)
^ Fourth + 1/4 turn Do not use a torque wrench for this step

NOTE: Bolt torque after 1/4 turn should be over 122 Nm (90 ft.lbs.). If not, replace the bolt.

6. Tighten head bolt number 9 Fig. 31 to 33 Nm (25 ft.lbs.) after head bolts 1 thorough 8 have been tighten to specifications.
7. Inspect push rods and replace worn or bent rods.

Fig. 32 Rocker Arm Shaft Retainers:

8. Install push rods, rocker arm and shaft assemblies with the stamped steel retainers in the four positions, tighten to 28 Nm (250 in.lbs.) Fig. 32.

CAUTION: The rocker arm shaft should be torqued down slowly, starting with the center bolts.

9. Place new cylinder head cover gaskets in position and install cylinder head covers. Tighten to 12 Nm (105 in.lbs.).

INTAKE MANIFOLD SEALING
The intake manifold gasket is a one-piece stamped steel gasket with a sealer applied from the manufacturer. This gasket has end seals incorporated with it.

WARNING: Intake manifold gasket is made of very thin metal and may cause personal injury. Handle with care.

1. Clean all surfaces of cylinder block and cylinder heads.

Fig. 33 Intake Manifold Gasket Sealing:

2. Place a drop (about 1/4 in. diameter) of Mopar Silicone Rubber Adhesive Sealant or equivalent, onto each of the four manifold to cylinder head gasket corners Fig. 33.

Fig. 34 Intake Manifold Gasket Retainers:

3. Carefully install the intake manifold gasket Fig. 34. Torque end seal retainer screws to 12 Nm - (105 in. lbs.).

Fig. 35 Intake Manifold Removal And Installation:

4. Install intake manifold and 8 bolts and torque to 1 Nm (10 in.lbs.). Then tighten bolts to 22 Nm (200 in.lbs.) in sequence shown in Fig. 35. Then tighten again to 22 Nm (200 in.lbs.). After intake manifold is in place, inspect to make sure seals are in place. Refer to Engine/Intake Manifold/Service and Repair to complete intake manifold assembly.
Service and Repair

5. Install exhaust manifolds and tighten bolts to 27 Nm (20 ft. lb.) and nuts to 20 Nm (15 ft.lbs.).
6. Adjust spark plugs to specification and install.