DODGE Chrysler Jeep 3.6L Cylinder Head Installation Guide

Engine, 3.6L
Cylinder Head
Installation Guide

LEFT

Special Tools: Click to display a list of tools used in this procedure

CAUTION: The magnetic timing wheels (1) must not come in contact with magnets (pickup tools, trays, etc.) or any other strong magnetic field. This will destroy the timing wheels’ ability to correctly relay the camshaft position to the camshaft position sensor.

1. If removed, install the Engine Coolant Temperature (ECT) sensor (4) and tighten it to 11 N·m (97 in. lbs.).

2. If removed, install the ignition coil capacitor (1) with an M6 bolt (2) tightened to 10 N·m (89 in. lbs.).

3. If removed, install the engine wire harness retainer bracket (5) with a T30 bolt (3) tightened to 12 N·m (106 in. lbs.). CAUTION: 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.
   NOTE: Typical cylinder head bolt shown.

4. Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced. NOTE: Right head gasket shown, left head gasket similar.
   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.

5. Clean and prepare the gasket sealing surfaces of the cylinder head and block (Refer to 09 – Engine – Standard Procedure).
   CAUTION: Non-compressible debris such as oil, coolant, or RTV sealants that are not removed from bolt holes can cause the aluminum casting to crack when tightening the bolts.

6. Clean out the cylinder head bolt holes in the engine block.
   WARNING: The multi-layered steel head gaskets have very sharp edges that could cause personal injury if not handled carefully.
   CAUTION: The installation of the cylinder head gaskets are not interchangeable between the left and right cylinder heads. They are clearly marked (3) with “R” for right and “L” for left. They must be applied on a dry surface, without the use of any adhesives.

7. Position the new cylinder head gasket (1) on the locating dowels (2).

8. Position the cylinder head onto the cylinder block.
   Make sure the cylinder head seats are fully over the locating dowels.
   NOTE: Do not apply any additional oil to the bolt threads.

9. Install the eight head bolts finger tight.

10. Tighten the cylinder head bolts in the sequence shown, following this 9-step torque plus angle method. Tighten according to the following torque values: Step 1: All to 30 N·m (22 ft. lbs.)
    Step 2: All to 45 N·m (33 ft. lbs.)
    Step 3: All + 75° Turn Do not use a torque wrench for this step.
    Step 4: All + 50° Turn Do not use a torque wrench for this step.
    Step 5: Loosen all fasteners in reverse of the sequence shown
    Step 6: All to 30 N·m (22 ft. lbs.)
    Step 7: All to 45 N·m (33 ft. lbs.)
    Step 8: All + 70° Turn Do not use a torque wrench for this step.
    Step 9: All + 70° Turn Do not use a torque wrench for this step. NOTE: If the hydraulic lifters are being reused, reassemble them into their original locations.

11. If removed, install the hydraulic lifters (Refer to 09 – Engine/Cylinder Head/LIFTER(S), Hydraulic Installation)
    NOTE: If the rocker’s arms are being reused, reassemble them into their original locations.

12. Install the rocker arms and camshafts (Refer to 09 – Engine/Cylinder Head/CAMSHAFT, Engine Installation)
    CAUTION: Do not rotate the camshafts more than a few degrees independently of the crankshaft. Valve-to-piston contact could occur resulting in possible valve damage. If the camshafts need to be rotated more than a few degrees, first move the pistons away from the cylinder heads by rotating the crankshaft counterclockwise to a position 30° before-top-dead-center. Once the camshafts are returned to their top-dead-center position, rotate the crankshaft clockwise to return the crankshaft to top-dead-center.

13. Rotate the camshafts CW to TDC by positioning the alignment holes (1) vertically.

14. Install the LH cam chain guide (2) with two bolts (4). Tighten the T30 bolts (4) to 12 N·m (106 in. lbs.).

15. Install the LH cam chain tensioner (5) to the cylinder head with two bolts (6). Tighten the T30 bolts (6) to 12 N·m (106 in. lbs.).

16. Reset the LH cam chain tensioner (5) by lifting the pawl (3), pushing back the piston, and installing Tensioner Pin 8514 (7) (Refer to 09 Engine/Valve Timing – Standard Procedure) .

17. Install the LH tensioner arm (1).

18. Press the LH intake cam phaser onto the intake camshaft. Install and hand-tighten the oil control valve.
    CAUTION: Always reinstall timing chains so that they maintain the same direction of rotation. Inverting a previously run chain on a previously run sprocket will result in excessive wear to both the chain and sprocket.

19. Drape the left side cam chain over the LH intake cam phaser and onto the idler sprocket (1) so that the arrow (3) is aligned with the plated link (2) on the cam chain.

20. While maintaining this alignment, route the cam chain around the exhaust and intake cam phasers so that the plated links are aligned with the phaser timing marks (1). Position the left side cam phasers so that the arrows (3) point toward each other and are parallel to the valve cover sealing surface (5). Press the exhaust cam phaser onto the exhaust cam, install and hand tighten the oil control valve (2).
    NOTE: Minor rotation of a camshaft (a few degrees) may be required to install the camshaft phaser or phaser lock.

21. Install the LH Camshaft Phaser Lock 10202 (4) and tighten the oil control valves (2) and (6) to 150 N·m (110 ft. lbs.).

22. Remove the LH Camshaft Phaser Lock 10202 .

23. Remove the Tensioner Pin 8514 (1) from the LH cam chain tensioner.

24. Rotate the crankshaft CW with two complete revolutions stopping when the dimple (4) on the crankshaft is aligned with the block/bearing cap junction (5).

25. While maintaining this alignment, verify that the arrows on the left side cam phasers (2) point toward each other and are parallel to the valve cover sealing surface (3) and that the right side cam phaser arrows (7) point away from each other and the scribe lines (9) are parallel to the valve cover sealing surface (8).

26. There should be 12 chain pins (2) between the exhaust cam phaser triangle marking (1) and the intake cam phaser circle marking (3).

27. If the engine timing is not correct, repeat this procedure.

28. Install the engine timing cover, crankshaft vibration damper, upper and lower oil pans, and cylinder head covers (Refer to 09 – Engine/Valve Timing/COVER(S), Engine Timing – Installation)

29. Install the LH upper intake manifold support brackets (1). Loosely install the stud bolts (2).

30. Engage two starter wire harness retainers (1) to the upper intake manifold support brackets.

31. Engage one main wire harness retainer (3) to the left cylinder head cover and two retainers (2) to the upper intake manifold support brackets.

32. Install the spark plugs. Tighten to 17.5 N·m (13 ft. lbs.) (Refer to 08 – Electrical/8I – Ignition Control/SPARK PLUG – Installation) .

33. Connect the ignition coil capacitor electrical connector.

34. Engage the injection/ignition harness connector (1) and the engine oil pressure/temperature harness connector (3) to the retainer bracket (2) on the rear of the left cylinder head.

35. Connect the Engine Coolant Temperature (ECT) sensor electrical connector (3).

36. Install the A/C compressor (2) with three bolts (1) tightened to 25 N·m (18 ft. lbs.).

37. Connect the A/C compressor electrical connector (1) and Engage the wire harness retainer (2) to the A/C compressor discharge line.

38. Install the accessory drive belt (4) (Refer to 07 Cooling/Accessory Drive/BELT, Serpentine Installation). NOTE: Right catalytic converter is shown, left catalytic converter is similar.

39. Install the left catalytic converter (2) onto the partially installed lower catalytic converter flange bolts (3).

40. Install the upper catalytic converter flange bolts (1) and tighten all M8 bolts to 23 N·m (17 ft. lbs.).

41. Connect the left upstream oxygen sensor connector (4) to the main wire harness.

42. Install the make-up air tube (3) to the left cylinder head cover and engage the clips (1) to the transmission breather hose (2).

43. Install the upper and lower intake manifolds (Refer to 09 – Engine/Manifolds/MANIFOLD, Intake – Installation)

44. Install the vapor purge tube (1) to the fuel purge solenoid (2) (Refer to 14 – Fuel System/Fuel Delivery/FITTING, Quick Connect – Standard Procedure)

45. Install the nut (2) to the support bracket of the heater core return tube (3) and tighten it to 12 N·m (106 in. lbs.). NOTE: Power steering pump not shown.

46. Raise and support the vehicle (Refer to 04 Vehicle Quick Reference/Hoisting – Standard Procedure) .

47. Install the A/C compressor mounting stud (2) and tighten to 25 N·m (18 ft. lbs.).

48. Install the nut (1) and bolt (4) to the support brackets of the heater core return tube (3). Tighten to 12 N·m (106 in. lbs.).

49. If equipped, install the front skid plate and front suspension skid plate (Refer to 13 – Frame and Bumpers/Under Body Protection).

50. Lower the vehicle.

51. Install the electric vacuum pump (4) and mounting bracket (1) (Refer to 05 Brakes/Electrical/PUMP, Electric Vacuum Installation).

52. Install the air inlet hose (3) and the air cleaner body (Refer to 09 – Engine/Air Intake System/BODY, Air Cleaner – Installation)

53. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level (Refer to 09 – Engine/Lubrication/OIL – Standard Procedure)

54. Fill the cooling system (Refer to 07 – Cooling Standard Procedure).

55. Install the engine cover (1).

56. Connect the negative battery cable and tighten the nut to 5 N·m (45 in. lbs.).

57. Run the engine until it reaches normal operating temperature. Check the cooling system for the correct fluid level (Refer to 07 – Cooling – Standard Procedure) NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example, flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

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6/4/2021

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