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Tuesday, May 8, 2012

How to replace Cylinder head on Dodge Ram Truck?

The Procedure for 5.2L & 5.9L Engine.
The Procedure mentioned Covers Dodge Ram 1500, 2500, 3500, 2WD & 4WD. Its For 2001 – 2005 Year Models.


  1. Drain the cooling system.
  2. Drain the engine oil.
  3. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.


    NOTE
    If the cylinder head is hot, gradually loosen the cylinder head bolts using the TIGHTENING sequence. If the engine is cold, then the loosening sequence for the head bolts is not important.


    NOTE
    The cylinder head bolts are different sizes. Note their locations for assembly.



    Negative battery cables
    Radiator hoses
    Heater hoses
    Drive belt
    Turbocharger
    Exhaust Gas Recirculation (EGR) tube
    Exhaust manifold
    Accelerator pedal position sensor
    Fuel lines and injector nozzles
    Valve cover



    Rocker levers and pedestal assemblies
    Pushrods
    Fuel filter and water separator assembly



    Cylinder head bolts
    Cylinder head
To install:

NOTE
Check the cylinder head bolt length. If length exceeds 5.2 inches (132.1 mm), the bolt must be replaced.

  1. Install or connect the following: 

    Cylinder head
    Pushrods
    Rocker levers and pedestal assemblies 

    image
    Fig. Cylinder head torque sequence-5.9L diesel engine
  2. Install the cylinder head bolts and tighten them in sequence as follows:
    1. Step 1: 59 ft. lbs. (80 Nm).
    2. Step 2: 77 ft. lbs. (104 Nm).
    3. Step 3: Retighten to 77 ft. lbs. (80 Nm).
    4. Step 4: Tighten an additional 90 degrees
  3. Install or connect the following:

    Fuel filter and water separator assembly
    Valve cover
    Fuel lines and injector nozzles
    Accelerator pedal position sensor
    Exhaust manifold
    EGR tube
    Turbocharger
    Drive belt
    Heater hoses
    Radiator hoses
    Negative battery cables
  4. Fill the crankcase to the correct level.
  5. Fill the cooling system.
  6. Start the engine and check for leaks.


==================================
5.2L & 5.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Remove or disconnect the following:
    NOTE
    Keep valvetrain components in order for reassembly.



    Negative battery cable
    Accessory drive belt
    Alternator
    A/C compressor, if equipped
    Air injection pump, if equipped
    Air cleaner assembly
    Closed Crankcase Ventilation (CCV) system
    Evaporative emissions control system
    Fuel line
    Accelerator linkage
    Cruise control cable
    Transmission cable
    Distributor cap and wires
    Ignition coil wiring
    Engine Coolant Temperature (ECT) sensor connector
    Heater hoses
    Bypass hose
    Upper radiator hose
    Intake manifold
    Valve covers



    Rocker arms
    Pushrods
    Exhaust manifolds
    Spark plugs
    Cylinder heads
To install:

WARNING
Position the crankshaft so that no piston is at Top Dead Center (TDC) prior to installing the cylinder heads. Do not rotate the crankshaft during or immediately after rocker arm installation. Wait 5 minutes for the hydraulic lash adjusters to bleed down.


image 
Fig. Cylinder head torque sequence-5.2L and 5.9L engines

  1. Install the cylinder heads. Use new gaskets and tighten the bolts in sequence as follows:
    1. Step 1: 50 ft. lbs. (68 Nm).
    2. Step 2: 105 ft. lbs. (143 Nm).
    3. Step 3: 105 ft. lbs. (143 Nm).
  2. Install or connect the following:

    Spark plugs
    Exhaust manifolds
    Pushrods and rocker arms in their original positions
    Valve covers
    Intake manifold
    Upper radiator hose
    Bypass hose
    Heater hoses
    ECT sensor connector
    Ignition coil wiring
    Distributor cap and wires
    Transmission cable
    Cruise control cable
    Accelerator linkage
    Fuel line
    Evaporative emissions control system
    CCV system
    Air cleaner assembly
    A/C compressor, if equipped
    Air injection pump, if equipped
    Alternator
    Accessory drive belt
    Negative battery cable
  3. Fill the cooling system.
  4. Start the engine and check for leaks.

These details will help.
Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html


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