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How to Replace Cylinder Head on 2007 Dodge Caliber?

The complete step by step details to remove/ install cylinder head for Dodge caliber car model is as follows:---


  1. Properly relieve the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Drain the cooling system.
  4. Remove the air intake assembly.
  5. Remove the engine appearance cover.
  6. Remove the coolant recovery bottle.
  7. Disconnect the power steering pump and reposition out of the way.
    NOTE
    Do not disconnect the power steering lines.
  8. Remove the windshield washer bottle.
  9. Disconnect the following:

    Breather hose
    Positive Crankcase Valve (PCV) hose
    Ignition coil electrical connectors
  10. Remove the cylinder head cover.
  11. Raise and safely support the vehicle.
  12. Remove the right engine splash shield.
  13. Rotate the engine to Top Dead Center (TDC).
  14. Remove the accessory drive belt.
  15. Remove the lower A/C compressor mounting bolts and lower mount.
  16. Remove the lower idler pulley.
  17. Remove the crankshaft damper.
  18. Remove the water pump pulley.
  19. Remove the right side engine mount bracket lower bolt.
  20. Remove the timing chain cover lower bolts.
  21. Disconnect the oxygen sensor electrical connector.
  22. Remove exhaust pipe at manifold nuts and remove pipe.
  23. Lower the vehicle.
  24. Support the engine with suitable jack.
  25. Remove right engine mount through bolt.
  26. Remove right engine mount to mount bracket bolts.
  27. Remove right engine mount adapter.
  28. Remove accessory drive upper idler pulley.
  29. Remove right upper engine mount bracket.
  30. Remove the accessory drive belt tensioner.
  31. Remove the upper timing chain cover retaining bolts.
  32. Remove the timing chain cover.
    NOTE
    If the timing chain plated links can no longer be seen, the timing chain links corresponding to the timing marks must be marked prior to removal if the chain is to be reused.
  33. Mark chain link corresponding to camshaft timing mark.
  34. Mark chain link corresponding to crankshaft timing mark.
  35. Remove the timing chain tensioner.
  36. Remove the timing chain.
  37. Remove the timing chain guides.
  38. Disconnect the fuel line at the fuel rail.
  39. Disconnect the fuel injector electrical connectors.
  40. Disconnect the top engine electrical connectors and reposition harness.
  41. Remove the fuel rail.
  42. Remove the throttle body support bracket retaining bolt.
  43. Disconnect the electronic throttle control electrical connector.
  44. Disconnect the MAP sensor electrical connector.
  45. Disconnect the vacuum lines at intake.
  46. Remove the intake manifold retaining bolts.
  47. Remove the upper radiator hose retaining bolt.
  48. Remove the intake manifold.
  49. Remove the coolant outlet manifold and set aside.
  50. Remove the ground strap at right rear of cylinder head.
  51. Remove the exhaust manifold. For additional information, refer to the following section, "Exhaust Manifold, Removal & Installation.-
  52. Remove the camshafts.
    NOTE
    All of the cylinder head bolts have captured washers EXCEPT the front two.
  53. Remove the cylinder head bolts.
  54. Remove the cylinder head from engine block.
To install:
  1. Replace the variable valve timing filter screen. 
    WARNING
    Always replace the variable valve timing filter screen when servicing the head gasket or engine damage could result.


    image
    Fig. Always replace the variable valve timing filter screen (3) in the cylinder head (1).
  2. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder block as shown. 

    image
    Fig. Before install the head gasket, place two dots of RTV (1) on the cylinder block as shown.
  3. Position the new cylinder head gasket on engine block with the part number facing up. Ensure gasket is seated over the locating dowels in block.
  4. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder head gasket as shown. 
    Fig. Cylinder head torque sequence-2.0L & 2.4L Engines
    image 
    Fig. After installing head gasket, place two more dots of RTV (1) on the cylinder block as shown.
  5. Position the cylinder head onto the engine block.
  6. Install washers for the front two cylinder head bolts.
  7. Lightly coat the cylinder head bolts with clean engine oil.
  8. Install the cylinder head bolts and tighten in sequence as follows:
    1. Tighten all bolts to 25 ft. lbs. (30 Nm).
    2. Tighten all bolts to 45 ft. lbs. (61 Nm).
    3. Tighten all bolts a second time to 45 ft. lbs. (61 Nm).
    4. Tighten all bolts an additional 90° 
      WARNING
      Do not use a torque wrench for last torque step.

  9. Install the exhaust manifold.
  10. Install the ground strap at the right rear of the cylinder head.
  11. Install the coolant adapter with new seals.
  12. Connect the coolant hoses.
  13. Connect the purge hose.
  14. Install the intake manifold and tighten to 18 ft. lbs. (25 Nm).
  15. Install the upper radiator hose retaining bracket bolt.
  16. Install the timing chain.
  17. Install the timing chain cover.
  18. Remove the ignition coils from cylinder head cover.
  19. Install the cylinder head cover.
  20. Connect the cam sensor wiring connector.
  21. Install the spark plugs and tighten to 20 ft. lbs. (27 Nm).
  22. Install ignition coils and tighten to 70 inch lbs. (8 Nm).
  23. Install the power steering pump reservoir.
  24. Install the windshield washer reservoir.
  25. Install the coolant recovery reservoir
  26. Install the accessory drive belt.
  27. Connect the engine coolant temperature sensor connector.
  28. Connect the coolant hoses to coolant adapter. Connect heater hoses to coolant adapter.
  29. Connect the coolant temperature sensor and capacitor electrical connectors.
  30. Install the heater tube support bracket to cylinder head.
  31. Install the fastener attaching dipstick tube to lower intake manifold.
  32. Connect the ignition coil and injector electrical connectors.
  33. Install the fuel rail.
  34. Connect fuel supply line quick-connect at the fuel rail assembly.
  35. Install the air intake assembly.
  36. Install the engine appearance cover.
  37. Refill the cooling system to the correct level.
  38. Refill the engine with oil to the correct level.
  39. Connect the negative battery cable.
  40. Start the engine and check for leaks.

These details will help.
Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html


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