2.7L Engines Cylinder head Replacing on Dodge Sprinter?

In this chapter details are provided to replace Cylinder head.
The procedure for dodge Sprinter Van/ Truck models with 2.7L Engine.

The details and help diagrams to perform this dis-assembly are as follows:---

2.7L Engines

1. Disconnect the negative battery cable.
2. Rotate the engine to put cylinder No. 1 at Top Dead Center (TDC).
3. Raise and safely support the vehicle.
4. Install Special Tool 8932 Retaining Lock on the crankshaft/starter ring gear to keep the engine from rotating.
5. Drain the cooling system.
6. Loosen the lower turbo support bracket bolt.
7. Remove the upper support bracket bolt.
8. Loosen the fasteners retaining the exhaust pipe to the support bracket at the rear of the engine.
9. Lower the vehicle.
10. Remove engine appearance cover.
11. Remove the camshafts. For additional information, refer to the following section, "Camshafts, Removal & Installation.-
12. Remove the camshaft housing at the cylinder head.
13. Remove the high pressure pump.
14. Remove the front head cover plate.
15. Remove the high pressure fuel pump intermediate gear.
16. Disconnect the engine side of the engine harness and set it aside.
17. Disconnect the charge air pipe at the cylinder head and set it aside with the engine harness connected.
18. Remove the turbocharger oil supply line at the cylinder head and turbocharger.
19. Disconnect the turbocharger at the exhaust manifold.
20. Unbolt the transmission oil level indicator tube fasteners from the cylinder head and engine block.
21. Disconnect the upper radiator hose and by pass hose at the thermostat housing.
    
    NOTE

    Have a shop rag ready to capture any fuel spillage when disconnecting fuel lines.
22. Disconnect the fuel line at the rear of the fuel rail.
23. Remove upper timing case to cylinder head bolts in the reverse order of the tightening sequence.
24. Remove the cylinder head mounting bolts.
25. Remove the cylinder head.

To install:

1. Clean all remaining gasket material from the mating surfaces. 
   
   
   
   Fig. Position the cylinder head (2) and gasket (4) over the dowel pins (2) and install the M12 bolts (1) and M8 bolts (5)-2.7L Engine
2. Position the cylinder head and gasket on the engine using the dowel pins as a guide.
3. Lightly coat the threads of each cylinder head mounting bolt with clean engine oil.
4. Start each bolt first by hand and then tighten as follows:
   1. Tighten the M12 bolts in sequence to 11 ft. lbs. (15 Nm).
   2. Tighten the M12 bolts in sequence to 44 ft. lbs. (60 Nm).
   3. Tighten the M8 bolts to 15 ft lbs. (20 Nm).
   4. Tighten the M12 bolts in sequence an additional 90°.
   5. Tighten the M12 bolts in sequence an additional 90° once more. 
      
      
      

      Fig. Cylinder head mounting bolts torque sequence-2.7L Engine
5. Install fuel return flow line between rail and high pressure pump.
6. Connect the coolant hoses to the thermostat housing.
7. Connect the coolant pipe to the cylinder head.
8. Reconnect transmission oil level indicator tube and tighten the mounting bolts to 10 ft. lbs. (14 Nm).
9. Reconnect the turbocharger to the exhaust manifold and tighten the mounting bolts to 22 ft. lbs. (30 Nm).
10. Install the oil return flow line with new seals at turbocharger. Tighten the supply line bolt to the turbocharger to 13 ft. lbs. (18Nm) and supply line bolt to the cylinder head to 80 inch lbs. (9 Nm).
11. Install the charge air distribution pipe.
12. Install and properly route the engine wiring harness, making appropriate connections.
13. Install the high pressure fuel pump intermediate gear and high pressure pump.
14. Install the camshaft housing with tappets to cylinder head.
15. Install the camshafts.
16. Install the top guide rail.
17. Install the front cover on the cylinder head.
18. Install the cylinder head cover.
19. Install the fuel high pressure pipes and injectors.
20. Install the timing chain tensioner with a new gasket. Tighten the bolts to 59 ft. lbs. (80 Nm).
21. Remove the Special Tool retaining lock for the crankshaft/starter ring gear.
22. Install the air intake tube at turbocharger.
23. Install the fasteners retaining the front exhaust pipe to the support bracket at the rear of the engine.
24. Install the upper support bracket fastener.
25. Install the lower turbo support bracket bolt.
26. Install engine appearance cover
27. Refill the cooling system to the correct level.
28. Connect the negative battery cable.
29. Start 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