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REMOVAL & INSTALLATION
1. Disconnect all wires, cable and hoses crossing the cylinder head cover. On the diesel engine, remove the air crossover tube.
WARNING
The V10 engine uses specially plated fasteners. Do not replace these with another type.
|Fig. 1: Upper: Remove whatever is in the way of cylinder head removal (V10 cover shown, |
|others similar). Lower: V10 engine bolt/stud arrangement |
|[pic] |
2. On V10 engines, remove the upper intake manifold to remove the right side cylinder head cover.
3. Remove the cylinder head cover bolts.
|Fig. 2: The steel-backed silicone cylinder head cover head gaskets are reusable — V10 |
|gasket shown, V6 and V8 models are similar |
|[pic] |
4. Using a soft mallet, tap loose the cylinder head cover.
|Fig. 3: Unbolt the cylinder head cover using a ratchet and extension |
|[pic] |
5. WARNING
Never pry the cover loose. You may damage the cover or head surface!
|Fig. 4: Remove the cover from the cylinder head and set it in a clean, safe location |
|[pic] |
6. Lift the cover off the engine.
7. Thoroughly clean all gasket material from the mating surfaces of the head and cover. On models which use RTV silicone sealant instead of a gasket, make sure that all material is removed.
To install:
8. On models using a conventional gasket, place a new gasket on the head, coated with sealer. Coat the cylinder head cover mating surface with sealer and install the cover.
9. On later models using a steel-backed silicon gasket, install the original gasket unless it has somehow been damaged.
10. Tighten the bolts to the following:
o V6 and V8 models with a conventional gasket: 4 ft. lbs. (4.5 Nm).
o 2.5L engine: 105 inch lbs. (12 Nm).
o On models with RTV silicone material, tighten the nuts to 80 inch lbs. (9 Nm); the studs to 10 ft. lbs. (13 Nm).
o V10 engine: 144 inch lbs. (16 Nm).
o V6 and V8 engines with steel-backed silicon gasket: 95 inch lbs. (11 Nm).
o Diesel engine: tighten the cylinder head cover bolts and air crossover tube bolts to 18 ft. lbs. (24 Nm).
Intake Manifold
REMOVAL & INSTALLATION
8.0L Engines
1. Drain the cooling system and disconnect the negative battery cable.
2. Remove alternator and air cleaner.
3. Remove the serpentine belt.
|Fig. 9: Details of the upper intake manifold and throttle body assembly—V10 engine |
|[pic] |
4. Remove the alternator and its brace.
5. Remove the air conditioning compressor brace, remove the compressor and set it aside without disconnecting the lines.
|Fig. 10: Details of the lower intake manifold—V10 engine |
|[pic] |
6. Remove the air cleaner cover and filter. Remove the filter. Discard the gasket.
7. Depressurize the fuel system and disconnect the fuel line.
8. Disconnect accelerator linkage, and if so equipped, the speed control and transmission kickdown cables.
|Fig. 11: Exploded view of the lower intake manifold gaskets—V10 engine |
|[pic] |
9. Remove the coil assemblies. Disconnect the vacuum lines.
10. Disconnect the heater hoses and bypass hose.
|Fig. 11: Align the intake manifold flange gasket—V10 engine |
|[pic] |
11. Remove the closed crankcase ventilation and evaporation control systems.
12. Remove throttle body and lift it off the upper intake manifold. Discard the gasket.
13. Remove the front upper intake manifold bolts. Retain the three rear bolts in the up position with tape or rubber bands.
14. Lift the upper intake manifold out of the engine bay. Discard the gasket.
15. Remove the lower intake manifold bolts and remove the manifold. Discard the gasket.
16. Installation is the reverse of removal. Clean the manifolds and mounting surfaces with solvent and let dry or dry completely with compressed air.
17. When sure that the block is oil-FREE, peel off the paper (blue-rear, brown-front) and press firmly onto the block. Align the slots in the end seals with the notches in the intake manifold gaskets.
18. Into each of the four corner pockets, insert Mopar® Silicon Rubber Adhesive Sealant, or equivalent. Do NOT overfill. The lower intake manifold must be installed within three minutes of the sealant's having been applied. After in place, inspect to be sure all the gaskets and the seals are in their proper places. Finger-start all lower intake bolts. Tighten in sequence to 40 ft. lbs. (54 Nm).
19. Install a new gasket and the upper intake manifold and finger-tighten all bolts. Alternate from one side to the other. Tighten the bolts to 16 ft. lbs. (22 Nm).
20. Install a new gasket and the throttle body onto the upper intake manifold. Tighten the bolts to 17 ft. lbs. (23 Nm). Fill the cooling system and connect the negative battery cable.
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