Sunday, April 22, 2012

How to replace Cylinder head ON Avenger, Stratus and Sebring?

The Complete Cylinder head removal For 2.5L Engine.

Please Note that this Procedure Covers all U.S. and Canadian models of the Chrysler/Dodge Avenger, Chrysler Sebring Coupe and Dodge Stratus/ Stratus Coupe models for Year 1999 to 2005.

The Procedure with details and Diagrams is as follows:---

  1. Properly relieve the fuel system pressure.
  2. Drain the cooling system.
  3. Remove or disconnect the following:

    Negative battery cable
    Timing belt and camshaft sprockets
    Wiring harnesses, vacuum hoses and lines that may inhibit cylinder head removal
    Intake manifold assembly
    Water pump inlet pipe retaining bolt from the inner rear of the front cylinder head
    Valve covers and rocker arm assemblies
    Distributor assembly
    Ground strap from the left end of the front cylinder head
    Exhaust manifolds and crossover pipe
    Cylinder head bolts; keep them in numbered order
    Cylinder head and discard the gasket
To install:
Fig. Install the head gasket with the identification mark at the front facing upward-2.5L engine

Fig. Cylinder head bolt tightening sequence-2.5L engine
  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean the oil passages thoroughly. Check the head for flatness. End-to-end, the head should be no more than 0.008 in. (0.2mm) out-of-true. If the service limit is exceeded, correct to meet specifications. Note that the maximum amount from stock allowed to be removed from the cylinder head and mating cylinder block is 0.0079 in. (0.2mm). If the cylinder head cannot be made serviceable by removing this amount, replace it.
  2. Check that the head gaskets have the proper identification marks for the engine. Lay the head gasket with the identification mark at the front top.
    Do not apply sealant to the head gasket or mating surfaces. Stretch-type cylinder head bolts are used. All new head bolts are recommended.
  3. Install the cylinder head straight down onto the block.
  4. Lubricate the bolts with clean engine oil.
  5. Install the bolts and the special washers by hand and just start each bolt one or 2 turns on the threads.
    The washers must be installed correctly. The rounded shoulder of the washer denotes the face in contact with the bolt. The flat side of the washer contacts the head.
  6. Torque the head bolts in the proper sequence as follows:
    1. Step1: 62 ft. lbs. (84 Nm).
    2. Step 2: 70 ft. lbs. (95 Nm).
    3. Step 3: 80 ft. lbs. (108 Nm).
  7. Install or connect the following:

    Valve cover and gasket
    Exhaust manifolds and crossover pipe
    Intake manifold
    All wiring harnesses, vacuum hoses and lines
    Negative battery cable
  8. Fill the cooling system. Changing the oil and filter is recommended to eliminate pollutants such as coolant in the oil.
  9. With the radiator cap off, start the engine and check for leaks of fuel, vacuum, oil or coolant. Check the operation of all engine electrical systems as well as dashboard gauges and lights. Add coolant as the engine warms.
  10. Perform necessary adjustments to the accelerator cable and drive belts. Allow the engine to cool and once again check and adjust the coolant level.

This engine uses aluminum alloy cylinder heads with 4-valves per cylinder and pressed-in cast iron valve guides. The cylinders are common to either cylinder bank. Two overhead camshafts are supported by 4 bearing journals which are part of the head with the distributor driven off the right (firewall side) cylinder head. Right and left camshaft drive sprockets are interchangeable. The sprockets and engine water pump are driven by the timing belt. Care must be taken to be sure all valve timing marks align after cylinder head and valve train service.

Please note that for camshaft service, the cylinder head must be removed.

Fig. Exploded view of the cylinder head, camshafts and rocker assemblies-2.5L engine

These details will help.


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