Dodge Durango

 Service Manual

Engine » Removal and installation
Cylinder heads

CYLINDER HEAD-LEFT

REMOVAL

(1) Disconnect the negative cable from the battery.

(2) Raise the vehicle on a hoist.

(3) Disconnect the exhaust pipe at the left side exhaust manifold.

(4) Drain the engine coolant. Refer to COOLING SYSTEM.

(5) Lower the vehicle.

(6) Remove the intake manifold. Refer to procedure in this section.

(7) Remove the cylinder head cover. Refer to procedure in this section.

(8) Remove the fan shroud and fan blade assembly.

Refer to COOLING SYSTEM.

(9) Remove accessory drive belt. Refer to COOLING SYSTEM.

(10) Remove the power steering pump and set aside.

(11) Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (Fig. 57).

Fig. 57 Engine Top Dead Center (TDC) Indicator Mark

1 - TIMING CHAIN COVER

2 - CRANKSHAFT TIMING MARKS

(12) Verify the V8 mark on the camshaft sprocket is at the 12 o'clock position (Fig. 59). Rotate the crankshaft one turn if necessary.

(13) Remove the crankshaft damper. Refer to Crankshaft Damper in this section.

(14) Remove the timing chain cover. Refer to procedure in this section.

(15) Lock the secondary timing chains to the idler sprocket using Special Tool 8515 (Fig. 58).

NOTE: Mark the secondary timing chain prior to removal to aid in installation.

(16) Mark the secondary timing chain, one link on each side of the V8 mark on the camshaft drive gear (Fig. 59).

(17) Remove the left side secondary chain tensioner.

Refer to Timing Chain and Sprockets in this section.

(18) Remove the cylinder head access plug (Fig.

60).

(19) Remove the left side secondary chain guide.

Refer to Timing Chain and Sprockets in this section.

(20) Remove the retaining bolt and the camshaft drive gear.

Fig. 58 Using Special Tool 8515 to Hold Chains to Idler Sprocket

1 - LOCK ARM

2 - RIGHT CAMSHAFT CHAIN

3 - SECONDARY CHAINS RETAINING PINS (4)

4 - IDLER SPROCKET

5 - LEFT CAMSHAFT CHAIN

6 - SPECIAL TOOL 8515

CAUTION: Do not allow the engine to rotate. Severe damage to the valve train can occur.

CAUTION: Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts.

NOTE: The cylinder head is attached to the cylinder block with fourteen bolts.

Fig. 60 Cylinder Head Access Plugs

1 - RIGHT CYLINDER HEAD ACCESS PLUG

2 - LEFT CYLINDER HEAD ACCESS PLUG

Fig. 59 Camshaft Sprocket V8 Marks

1 - LEFT CYLINDER HEAD

2 - RIGHT CYLINDER HEAD

(21) Remove the cylinder head retaining bolts.

(22) Remove the cylinder head and gasket. Discard the gasket.

CAUTION: Do not lay the cylinder head on its gasket sealing surface, due to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from properly sealing resulting in leaks.

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 should be replaced.

Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced (Fig. 61).

Fig. 61 Checking Cylinder Head Bolts for Stretching (Necking)

1 - STRETCHED BOLT

2 - THREADS ARE NOT STRAIGHT ON LINE

3 - THREADS ARE STRAIGHT ON LINE

4 - UNSTRETCHED BOLT

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.

(1) Clean the cylinder head and cylinder block mating surfaces (Fig. 62).

(2) Position the new cylinder head gasket on the locating dowels.

CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.

(3) Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.

Fig. 62 Proper Tool Usage for Surface Preparation

1 - PLASTIC/WOOD SCRAPER

NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.

(4) Lubricate the cylinder head bolt threads with clean engine oil and install the ten M11 bolts.

(5) Coat the four M8 cylinder head bolts with Mopart Lock and Seal Adhesive then install the bolts.

NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.

(6) Tighten the bolts in sequence (Fig. 63) using the following steps and torque values:

• Step 1: Tighten bolts 1-10, 20 N*m (15 ft. lbs.).
• Step 2: Tighten bolts 1-10, 47 N*m (35 ft. lbs.).

  Tighten bolts 11-14, 25 N*m (18 ft. lbs.).

• Step 3: Tighten bolts 1-10, 90 degrees. Tighten bolts 11-14, 30 N*m (22 ft. lbs.).

(7) Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V8 mark on the gear and position the gear onto the camshaft.

(8) Install the camshaft drive gear retaining bolt.

(9) Install the left side secondary chain guide.

(10) Install the cylinder head access plug.

(11) Re-set and Install the left side secondary chain tensioner.

(12) Remove Special Tool 8515.

(13) Install the timing chain cover.

Fig. 63 Cylinder Head Tightening Sequence

(14) Install the crankshaft damper. Tighten damper bolt 175 N*m (130 Ft. Lbs.).

(15) Install the power steering pump.

(16) Install the fan blade assembly and fan shroud.

(17) Install the cylinder head cover.

(18) Install the intake manifold.

(19) Refill the cooling system (20) Raise the vehicle.

(21) Install the exhaust pipe onto the left exhaust manifold.

(22) Lower the vehicle.

(23) Connect the negative cable to the battery.

(24) Start the engine and check for leaks.

CYLINDER HEAD-RIGHT

REMOVAL

(1) Disconnect battery negitive cable.

(2) Raise the vehicle on a hoist.

(3) Disconnect the exhaust pipe at the right side exhaust manifold.

(4) Drain the engine coolant. Refer to COOLING SYSTEM.

(5) Lower the vehicle.

(6) Remove the intake manifold. Refer to procedure in this section.

(7) Remove the cylinder head cover. Refer to procedure in this section.

(8) Remove the fan shroud. Refer to COOLING SYSTEM.

(9) Remove oil fill housing from cylinder head.

(10) Remove accessory drive belt. Refer to COOLING SYSTEM.

(11) Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (Fig. 57).

(12) Verify the V8 mark on the camshaft sprocket is at the 12 o'clock position (Fig. 59). Rotate the crankshaft one turn if necessary.

(13) Remove the crankshaft damper. Refer to Crankshaft Damper in this section.

(14) Remove the timing chain cover. Refer to Timing Chain Cover in this section.

(15) Lock the secondary timing chains to the idler sprocket using Special Tool 8515 (Fig. 58).

NOTE: Mark the secondary timing chain prior to removal to aid in installation.

(16) Mark the secondary timing chain, one link on each side of the V8 mark on the camshaft drive gear (Fig. 59).

(17) Remove the right side secondary chain tensioner.

Refer to Timing Chain and Sprockets in this section.

(18) Remove the cylinder head access plug (Fig.

64).

Fig. 64 Cylinder Head Access Plugs

1 - RIGHT CYLINDER HEAD ACCESS PLUG

2 - LEFT CYLINDER HEAD ACCESS PLUG

(19) Remove the right side secondary chain guide.

Refer to Timing Chain and Sprockets in this section.

(20) Remove the retaining bolt and the camshaft drive gear.

CAUTION: Do not allow the engine to rotate. severe damage to the valve train can occur.

CAUTION: Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts.

CAUTION: Do not hold or pry on the camshaft target wheel for any reason. A damaged target wheel can result in a vehicle no start condition.

NOTE: The cylinder head is attached to the cylinder block with fourteen bolts.

(21) Remove the cylinder head retaining bolts.

(22) Remove the cylinder head and gasket. Discard the gasket.

CAUTION: Do not lay the cylinder head on its gasket sealing surface, do to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from properly sealing resulting in leaks.

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 should be replaced.

Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced (Fig. 61).

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.

(1) Clean the cylinder head and cylinder block mating surfaces (Fig. 65).

Fig. 65 Proper Tool Usage For Surface Preparation

1 - PLASTIC/WOOD SCRAPER

(2) Position the new cylinder head gasket on the locating dowels.

CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.

(3) Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.

NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.

(4) Lubricate the cylinder head bolt threads with clean engine oil and install the ten M10 bolts.

(5) Coat the four M8 cylinder head bolts with Mopar Lock and Seal Adhesive then install the bolts.

NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.

(6) Tighten the bolts in sequence (Fig. 66) using the following steps and torque values:

• Step 1: Tighten bolts 1-10, 20 N*m (15 ft. lbs.).
• Step 2: Tighten bolts 1-10, 47 N*m (35 ft. lbs.).

  Tighten bolts 11-14, 25 N*m (18 ft. lbs.)

• Step 3: Tighten bolts 1-10, 90 degrees. Tighten bolts 11-14, 30 N*m (22 ft. lbs.).

Fig. 66 Cylinder Head Tightening Sequence

(7) Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V8 mark on the gear and position the gear onto the camshaft.

(8) Install the camshaft drive gear retaining bolt.

(9) Install the right side secondary chain guide.

(10) Install the cylinder head access plug.

(11) Re-set and install the right side secondary chain tensioner.

(12) Remove Special Tool 8515.

(13) Install the timing chain cover.

(14) Install the crankshaft damper. Tighten damper bolt 175 N*m (130 Ft. Lbs.).

(15) Install accessory drive belt.

(16) Install the fan shroud.

(17) Install the cylinder head cover.

(18) Install the intake manifold.

(19) Install oil fill housing onto cylinder head.

(20) Refill the cooling system.

(21) Raise the vehicle.

(22) Install the exhaust pipe onto the right exhaust manifold.

(23) Lower the vehicle.

(24) Reconnect battery negitive cable.

(25) Start the engine and check for leaks.

Engine mounts-left and right

Engine mount-rear

Structural cover

Engine assembly

Intake manifold

Exhaust manifolds

Cylinder head cover

Rocker arms

Cylinder heads

Valve springs and seals

Hydraulic lash adjuster

Crankshaft damper

Timing chain cover

Timing chain and sprockets

Idler shaft-timing drive

Camshafts-in vehicle

Crankshaft main bearings

Oil pan 4x2 vehicle

Oil pan 4x4 vehicle

Piston and connecting rod

Crankshaft

Flexplate

Oil pump

Engine oil pressure sending unit

Crankshaft oil seal-front

Crankshaft oil seal-rear

Engine core plugs