Removal and Installation

REMOVAL
1. Drain cooling system and disconnect negative cable from battery.
2. Remove upper and lower intake manifolds.

WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE.

3. Disconnect coil wires, sending unit wire, heater hoses and bypass hose.
4. Remove PCV system hoses, evaporation control system hose and cylinder head covers.
5. Remove exhaust manifolds.
6. Remove rocker arm and shaft assemblies. Remove push rods and mark positions to ensure installation in original locations.

Cylinder Head Bolts Location And Tightening Sequence:

7. Remove the 9 head bolts from each cylinder head and remove cylinder heads.

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

Head Gasket Installation:

2. Install new gaskets on cylinder block.

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.
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.
5. Tighten the cylinder head bolts 1-8 in the sequence shown in image. Using the 4 step torque turn method, tighten according to the following values:
- Step 1: Bolts 1-8 to 61 Nm (45 ft. lbs.)
- Step 2: Bolts 1-8 to 88 Nm (65 ft. lbs.)
- Step 3: Bolts 1-8 (again) to 88 Nm (65 ft. lbs.)
- Step 4: Bolts 1-8 turn an additional 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 to 33 Nm (25 ft. lbs.) after head bolts 1-8 have been tighten to specifications.
7. Inspect push rods and replace worn or bent rods.

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

Intake Manifold Gasket Sealing:

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

Intake Manifold Gasket Retainers:

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

Intake Manifold Removal And Installation:

4. Install intake manifold and (8) bolts and torque to 1 Nm (10 inch lbs.). Then tighten bolts to 22 Nm (200 inch lbs.) in sequence shown in image. Then tighten again to 22 Nm (200 inch lbs.). After intake manifold is in place, inspect to make sure seals are in place.
5. Install exhaust manifolds and tighten bolts to 27 Nm (20 ft. lbs.) and nuts to 20 Nm (15 ft. lbs.).
6. Adjust spark plugs to specification and install the plugs.