Replace Dodge Sprinter Van/Truck Model Cylinder head.
The procedure for 3.5L Engine models.
The complete procedure with details and diagrams:---
The Cylinder head removal/ install is as follows:----
3.5L Engine
Car repair guide?
http://technoanswers.blogspot.in/2012/03/car-repair-guide.html
The procedure for 3.5L Engine models.
The complete procedure with details and diagrams:---
The Cylinder head removal/ install is as follows:----
3.5L Engine
- Disconnect the negative battery cable.
- Properly relieve the fuel system pressure.
- Drain the cooling system.
- Drain the engine oil.
- Remove the air intake assembly.
- Remove the accessory drive belt. For additional information, refer to the following section, "Accessory Drive Belt, Removal & Installation.-
- Rotate the engine in a clockwise direction until the No. 1 cylinder is at 40 degrees after Top Dead Center (TDC).
- Raise and safely support the vehicle.
- Remove the lower sound shield.
- Remove the catalytic converter to manifold mounting bolts.
- Remove the timing chain tensioner.
- Lower the vehicle.
- Disconnect the upper radiator hose from the engine.
- Remove the fan and fan shroud assembly.
- Disconnect the canister purge line from the engine.
- Remove the air intake housing support.
- Remove the evaporative emissions vacuum lines.
- Remove the fuel rail and fuel injectors. For additional information, refer to the following section, "Fuel Injectors, Removal & Installation.-
- Disconnect and remove the Powertrain Control Module (PCM).
- Remove the left and right PCM bracket.
- Position aside the remote battery positive terminal connection.
- Disconnect the engine wiring harness ground from the cylinder head.
- Remove the three ignition coils from the cylinder head. For additional information, refer to the following section, "Ignition Coil, Removal & Installation.-
- Remove the intake manifold. For additional information, refer to the following section, "Intake Manifold, Removal & Installation.-
- Remove the air injection valve bolts.
- Remove the air injection adapter bolts.
- Remove the hoses from the air injection pump.
- Remove the air injection pump and bracket.
- Remove the upper idler pulleys.
- Remove the accessory drive tensioner pulley bolts.
- Remove the accessory drive tensioner pulley.
- Remove the oil cooler housing bolts and remove the oil cooler housing.
- Disconnect the right head camshaft position sensors.
- Remove the right head camshaft position sensors.
- Disconnect the left head camshaft position sensors.
- Remove the left head camshaft position sensors.
- Remove the left upper front cover.
- Remove the left cylinder head cover.
- Remove the camshafts. For additional information, refer to the following section, "Camshafts, Removal & Installation.-
- Use a slide hammer to remove the timing chain slide rail pins from the cylinder head.
- Remove the timing chain slide rail.
- Loosen all of the cylinder head bolts in the reverse order of the tightening sequence.
- Remove the cylinder head bolts and remove cylinder head.
- Place the cylinder head on wooden blocks on the bench and remove the exhaust manifold if necessary.
To install:
- If removed, install the exhaust manifold to the cylinder and tighten the nuts to 12 ft. lbs. (16 Nm).
- Clean any old gasket material from the mating surfaces.
- Install the cylinder head with a new gasket.
- Install the cylinder head-to-timing chain front cover bolts to 18 ft. lbs. (25 Nm) plus 90°
- Install the cylinder head mounting bolts in a spiral pattern as follows:
Step 1: Tighten to 15 ft. lbs. (20 Nm)Step 2: Tighten to 29 ft. lbs. (44 Nm)Step 3: Tighten to 29 ft. lbs. (44 Nm) againStep 4: Tighten an additional 90°Step 5: Tighten an additional 90° again - Install the timing chain slide rail.
- Install the timing chain slide rail pins into the cylinder head.
- Install the camshafts. For additional information, refer to the following section, "Camshafts, Removal & Installation.-
- Install the cylinder head cover as follows:
- Remove any old gasket material from the sealing surfaces of the cylinder head cover.
- Apply a thin layer of silicone sealant to the cylinder head cover mating surface.
- Install the cylinder head cover with new bolts and tighten them in the sequence shown to 106 inch lbs. (12 Nm).
- Tighten all of the bolts in sequence in additional 90°
- Install the upper front cover as follows:
- Clean any old gasket material from the mating surfaces.
- Apply silicone sealant to the upper front cover sealing surface.
- Install the upper front cover and tighten the mounting bolts to 80 inch lbs. (9 Nm).
- Install the camshaft position sensors.
- Install the air injection pump and bracket.
- Install the air injection valve.
- Install the hoses to the air injection pump.
- Install the oil cooler housing and tighten the bolts to 18 ft. lbs. (25 Nm).
- Install the accessory drive tensioner pulley and tighten the bolts to 26 ft. lbs. (35 Nm)
- Install the upper idler pulleys.
- Install the intake manifold.
- Install the ignition coils and connect the electrical connectors.
- Route the engine wiring harness in its original position and tighten the harness bolts to 71 inch lbs. (8 Nm).
- Install the PCM mounting bolts brackets, the install and connect the PCM electrical connectors.
- Install the fuel rail and fuel injectors.
- Install the vacuum line to the fuel pressure regulator.
- Install the intake air housing support.
- Connect the remote battery positive terminal connection.
- Connect the canister purge line to the engine.
- Install the fan assembly.
- Connect the upper radiator hose to the engine.
- Install the lower sound shield.
- Install the accessory drive belt.
- Lower the vehicle.
- Refill the engine with oil to the correct level.
- Refill the cooling system to the correct level.
- Connect the negative battery cable.
- Start the engine and check for leaks.
These details will help.
Thanks.
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