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Cylinder Head: Installation

NOTE: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced (Fig 1)

Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt must be replaced (Fig 1)

CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT  use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.
Fig 1: Checking For Stretched Bolts
G00990747Courtesy of DAIMLERCHRYSLER CORP.
  1. Clean sealing surfaces of cylinder head and block. (Refer to STANDARD PROCEDURE )
  2. Install new head gasket over locating dowels.
  3. Install cylinder head to block, assuring head is properly positioned over locating dowels.
  4. Lubricate bolt threads with clean engine oil and install bolts.
  5. Tighten bolts in sequence shown in (Fig 2), using the following steps and torque values:
    • Step 1: Bolts 1-8 to 48 N.m (35 ft. lbs.)
    • Step 2: Bolts 1-8 to 75 N.m (55 ft. lbs.)
    • Step 3: Bolts 1-8 to 75 N.m (55 ft. lbs.)
    • Step 4: Bolts 1-8 to +90° Turn Do not use a torque wrench for this step. 
    • Step 5: Bolts 9-11 to 28 N.m (250 in. lbs.)
      Fig 2: Identifying Cylinder Head Tightening Sequence
      G00990748Courtesy of DAIMLERCHRYSLER CORP.
  6. Connect catalytic converter to exhaust manifold with a new V-Band clamp. Tighten V-Band clamp to 10 N.m (100 in. lbs.).
  7. Install all valvetrain components and camshafts. (Refer to CAMSHAFT(S) ) Tighten camshaft bearing caps in sequence shown in (Fig 3)
    Fig 3: Identifying Camshaft Bearing Cap Tightening Sequence
    G00990749Courtesy of DAIMLERCHRYSLER CORP.
  8. Install timing chain and sprockets. (Refer to TIMING BELT/CHAIN AND SPROCKETS )
  9. Install water outlet connector (Figure). (Refer to COOLANT OUTLET CONNECTOR - 2.7L )
  10. Install cylinder head covers. (Refer to CYLINDER HEAD COVER(S) )
  11. Install timing chain cover and crankshaft vibration damper. (Refer to TIMING CHAIN COVER ) (Refer to VIBRATION DAMPER )
  12. Install lower and upper intake manifolds. (Refer to INTAKE MANIFOLD - LOWER  and INTAKE MANIFOLD - UPPER N)
  13. Install accessory drive belts. (Refer to DRIVE BELTS - 2.7L )
  14. Fill cooling system. (Refer to STANDARD PROCEDURE - COOLING SYSTEM FILLING )
  15. Connect negative cable to remote jumper terminal.
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