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Thursday, April 19, 2012

Dodge Sprinter 3.5L Cylinder head removal?

Replace Dodge Sprinter Van/Truck Model Cylinder head.
The procedure for 3.5L Engine models.

The complete procedure with details and diagrams:---

The Cylinder head removal/ install is as follows:----


3.5L Engine
  1. Disconnect the negative battery cable.
  2. Properly relieve the fuel system pressure.
  3. Drain the cooling system.
  4. Drain the engine oil.
  5. Remove the air intake assembly.
  6. Remove the accessory drive belt. For additional information, refer to the following section, "Accessory Drive Belt, Removal & Installation.-
  7. Rotate the engine in a clockwise direction until the No. 1 cylinder is at 40 degrees after Top Dead Center (TDC).
  8. Raise and safely support the vehicle.
  9. Remove the lower sound shield.
  10. Remove the catalytic converter to manifold mounting bolts.
  11. Remove the timing chain tensioner.
  12. Lower the vehicle.
  13. Disconnect the upper radiator hose from the engine.
  14. Remove the fan and fan shroud assembly.
  15. Disconnect the canister purge line from the engine.
  16. Remove the air intake housing support.
  17. Remove the evaporative emissions vacuum lines.
  18. Remove the fuel rail and fuel injectors. For additional information, refer to the following section, "Fuel Injectors, Removal & Installation.-
  19. Disconnect and remove the Powertrain Control Module (PCM).
  20. Remove the left and right PCM bracket.
  21. Position aside the remote battery positive terminal connection.
  22. Disconnect the engine wiring harness ground from the cylinder head.
  23. Remove the three ignition coils from the cylinder head. For additional information, refer to the following section, "Ignition Coil, Removal & Installation.-
  24. Remove the intake manifold. For additional information, refer to the following section, "Intake Manifold, Removal & Installation.-
  25. Remove the air injection valve bolts.
  26. Remove the air injection adapter bolts.
  27. Remove the hoses from the air injection pump.
  28. Remove the air injection pump and bracket.
  29. Remove the upper idler pulleys.
  30. Remove the accessory drive tensioner pulley bolts.
  31. Remove the accessory drive tensioner pulley.
  32. Remove the oil cooler housing bolts and remove the oil cooler housing.
  33. Disconnect the right head camshaft position sensors.
  34. Remove the right head camshaft position sensors.
  35. Disconnect the left head camshaft position sensors.
  36. Remove the left head camshaft position sensors.
  37. Remove the left upper front cover.
  38. Remove the left cylinder head cover.
  39. Remove the camshafts. For additional information, refer to the following section, "Camshafts, Removal & Installation.-
  40. Use a slide hammer to remove the timing chain slide rail pins from the cylinder head.
  41. Remove the timing chain slide rail.
  42. Loosen all of the cylinder head bolts in the reverse order of the tightening sequence.
  43. Remove the cylinder head bolts and remove cylinder head.
  44. Place the cylinder head on wooden blocks on the bench and remove the exhaust manifold if necessary.
To install:
  1. If removed, install the exhaust manifold to the cylinder and tighten the nuts to 12 ft. lbs. (16 Nm).
  2. Clean any old gasket material from the mating surfaces.
  3. Install the cylinder head with a new gasket.
  4. Install the cylinder head-to-timing chain front cover bolts to 18 ft. lbs. (25 Nm) plus 90° 

    image
    Fig. Install the two cylinder head-to-front cover bolts (1) before the rest of the cylinder head mounting bolts-3.5L Engine cylinder head installation
  5. Install the cylinder head mounting bolts in a spiral pattern as follows:

    Step 1: Tighten to 15 ft. lbs. (20 Nm)
    Step 2: Tighten to 29 ft. lbs. (44 Nm)
    Step 3: Tighten to 29 ft. lbs. (44 Nm) again
    Step 4: Tighten an additional 90°
    Step 5: Tighten an additional 90° again
  6. Install the timing chain slide rail.
  7. Install the timing chain slide rail pins into the cylinder head.
  8. Install the camshafts. For additional information, refer to the following section, "Camshafts, Removal & Installation.-
  9. Install the cylinder head cover as follows:
    1. Remove any old gasket material from the sealing surfaces of the cylinder head cover.
    2. Apply a thin layer of silicone sealant to the cylinder head cover mating surface.
    3. Install the cylinder head cover with new bolts and tighten them in the sequence shown to 106 inch lbs. (12 Nm). 

      Click image to see an enlarged view
      Fig. Cylinder head cover torque sequence-3.5L cylinder head cover
    4. Tighten all of the bolts in sequence in additional 90°
  10. Install the upper front cover as follows:
    1. Clean any old gasket material from the mating surfaces.
    2. Apply silicone sealant to the upper front cover sealing surface.
    3. Install the upper front cover and tighten the mounting bolts to 80 inch lbs. (9 Nm).
  11. Install the camshaft position sensors.
  12. Install the air injection pump and bracket.
  13. Install the air injection valve.
  14. Install the hoses to the air injection pump.
  15. Install the oil cooler housing and tighten the bolts to 18 ft. lbs. (25 Nm).
  16. Install the accessory drive tensioner pulley and tighten the bolts to 26 ft. lbs. (35 Nm)
  17. Install the upper idler pulleys.
  18. Install the intake manifold.
  19. Install the ignition coils and connect the electrical connectors.
  20. Route the engine wiring harness in its original position and tighten the harness bolts to 71 inch lbs. (8 Nm).
  21. Install the PCM mounting bolts brackets, the install and connect the PCM electrical connectors.
  22. Install the fuel rail and fuel injectors.
  23. Install the vacuum line to the fuel pressure regulator.
  24. Install the intake air housing support.
  25. Connect the remote battery positive terminal connection.
  26. Connect the canister purge line to the engine.
  27. Install the fan assembly.
  28. Connect the upper radiator hose to the engine.
  29. Install the lower sound shield.
  30. Install the accessory drive belt.
  31. Lower the vehicle.
  32. Refill the engine with oil to the correct level.
  33. Refill the cooling system to the correct level.
  34. Connect the negative battery cable.
  35. 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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