Head Gasket - Improved Design/Installation
NO: 09-05-98GROUP: Engine
EFFECTIVE DATE: Nov. 6, 1998
SUBJECT:
Multi-Layer Steel (MLS)
Head Gasket installation
Procedures
MODELS:
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1995 - 1999 (PL) Neon
1997 - 1999 (GS) Chrysler Voyager (International Market)
NOTE:
THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR 2.4L ENGINE.
DISCUSSION:
A new Multi-Layer Steel (MLS) head gasket has been developed and is being implemented into production vehicles. Additionally, it has been approved for service applications.
This new gasket will provide superior sealing characteristics, but will require extra care in its installation where a composite gasket was previously in place. The following steps will assist service technicians in the proper installation of this MLS gasket.
CAUTION:
ALUMINUM ENGINE COMPONENTS ARE VERY SUSCEPTIBLE TO METAL TRANSFER AND SURFACE DAMAGE WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. EXERCISE EXTREME CARE WHEN CLEANING THESE COMPONENTS. THE MLS GASKET CANNOT PROPERLY SEAL IF GOUGING OF THE SURFACES, METAL TRANSFER HAS TAKEN PLACE, OR COMPOSITE GASKET MATERIAL IS LEFT ON THE HEAD OR BLOCK SURFACES.
PARTS/EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
This bulletin explains the proper procedures for preparing head/block surfaces for MLS gasket installation.
1. Following service manual procedures, remove the head.
2. Remove as much of the loose composite gasket material with a plastic or wooden scraper.
NOTE:
PRIOR TO ADDITIONAL CLEANING, INSPECT THE COOLING PASSAGES OF THE HEAD. REPLACEMENT OF THE HEAD MAY BE REQUIRED IF PITTING/EROSION HAS TAKEN PLACE THAT WILL COMPROMISE THE SEALING SURFACES AROUND THE PASSAGES.
3. Cover coolant and oil passages and apply solvent or a commercially available gasket cleaner to the head/block surfaces. Allow the solvent to soften the remaining composite gasket residue.
4. Using a plastic or wooden scraper, scrape any large amounts of gasket residue from the surfaces. If necessary, apply additional solvent/gasket remover to ease removal.
5. If additional cleaning is needed, use a drill motor and 3M roloc bristle disc p/n 07528 (white) carefully remove remaining gasket material from head/block surfaces.
NOTE:
IF DIFFICULT TO REMOVE RESIDUE IS LEFT, THE YELLOW ROLOC BRISTLE DISK 3M P/N 07525 CAN BE USED. USE EXTREME CARE WHEN POWER CLEANING ALUMINUM SURFACES. EXCESS CLEANING PRESSURE OR HIGH RPM CAN CAUSE ALUMINUM TRANSFER.
6. Inspect the sealing surfaces for any composite gasket residue. Carefully remove remaining material.
7. The head and block must be checked for flatness. Follow service manual procedures/specifications where applicable. Machine or replace components as necessary.
8. Spray both sides of the MLS gasket with a coat of MOPAR spray gasket sealant p/n 04318035.
9. Re-assemble the engine as outlined in the appropriate service manual. Pay particular attention to head bolt torque and torquing procedures.
CAUTION:
THE 2.0L DOHC CYLINDER HEAD BOLT TORQUE AND TORQUING PROCEDURE HAS CHANGED FOR THE MLS GASKET. THE TORQUE SPECIFICATIONS AND PROCEDURES FOR THE 2.0L DOHC MUST BE CHANGED AS FOLLOWS: ALL HEAD BOLTS SHOULD BE OILED PRIOR TO ASSEMBLY, THE FOUR SHORT BOLTS ARE INSTALLED IN THE CORNER HOLES. TORQUE SEQUENCE IS SHOWN IN FIGURE 1.
1. TORQUE ALL CENTER BOLTS TO 34 NM (25 FT LBS.), TORQUE THE 4 CORNER BOLTS TO 27 NM (20 FT LBS.).
2. TORQUE ALL CENTER BOLTS TO 68 NM (50 FT LBS.), TORQUE THE 4 CORNER BOLTS TO 47 NM (35 FT LBS.).
3. RE-TORQUE ALL CENTER BOLTS TO 68 NM (50 FT LBS.), TORQUE THE 4 CORNER BOLTS TO 47 NM (35 FT LBS.).
4. TIGHTEN ALL BOLTS IN THE SPECIFIED SEQUENCE AN ADDITIONAL 90° (1/4 TURN).
10. Be sure to install a new cam sensor seal on all engine applications.
NOTE:
A NEW CAM SENSOR SEAL MUST BE INSTALLED DURING THE HEAD GASKET REPLACEMENT PROCEDURE. OIL SEEPAGE FROM THIS SEAL CAN BE MISINTERPRETED AS A HEAD GASKET LEAK.
POLICY: Information Only