Chrysler Town, Dodge Caravan. Manual — part 1092
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION
(1) Use special tool VM.1010 with dial indicator
special tool VM.1013 (Fig. 14).
(2) Bring the piston of cylinder no. 1 exactly to top
dead center.
(3) Zero the dial indicator on the cylinder block
mating surface.
(4) Setup the dial indicator on the piston crown
(above the center of the piston pin) 5mm (1/8 in.)
from the edge of the piston and note the measure-
ment.
(5) Repeat the procedure with the rest of the cyl-
inders.
(6) Establish the thickness of the steel gasket by
averaging the four piston potrusion readings.
Measure Dimension
(mm)
0.49-0.60
Cylinder Head Gasket
Thickness (mm)
1.32
No Holes or Notches
Piston Clearance (mm)
0.72-0.83
Measure Dimension
(mm)
0.61-0.70
Cylinder Head Gasket
Thickness (mm)
1.42
1 Hole or Notch
Piston Clearance (mm)
0.72-0.81
Measure Dimension
(mm)
0.71-0.83
Cylinder Head Gasket
Thickness (mm)
1.52
2 Holes or Notches
Piston Clearance (mm)
0.69-0.81
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(7) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
(8) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
Fig. 13 VALVE GUIDE HEIGHT
Fig. 14 PISTON PROTRUSION
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ENGINE
9 - 21
CYLINDER HEAD (Continued)
CAUTION: Before removing the cylinder head cover/
intake manifold or timing belt the engine must put
at 90° after TDC. Failure to do so could result in
valve and/or piston damage during reassembly.
(Refer to 9 - ENGINE/VALVE TIMING - STANDARD
PROCEDURE)
(9) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(10) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(11) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(12) Remove cylinder head cover/intake manifold
(Fig. 15)(Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - REMOVAL).
(13) Remove rocker arm and lifter assemblies from
cylinder head.
(14) Remove cylinder head cover/intake manifold
gasket from cylinder head.
(15) Disconnect glow plug and engine coolant tem-
perture electrical connectors.
(16) Remove coolant recovery pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - REMOVAL).
(17) Remove thermostat housing to upper radiator
hose pipe (Fig. 16).
(18) Remove turbocharger outlet to charge air
cooler pipe (Fig. 16).
Fig. 15 CYLINDER HEAD COVER/INTAKE
MANIFOLD ASSEMBLY
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(LONG)
2 - CYLINDER HEAD COVER/INTAKE MANIFOLD
3 - CYLINDER HEAD
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD GASKET
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(SHORT)
Fig. 16 TURBOCHARGER AND COOLANT PIPES
1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT
2 - TURBOCHARGER OUTLET PIPE
3 - ADAPTOR HOSE
4 - HOSE CLAMPS
5 - TURBOCHARGER INLET PIPE RETAINING BOLT
6 - TURBOCHARGER INLET PIPE
7 - ADAPTOR HOSE
8 - HOSE CLAMPS
9 - EGR VALVE TO INTAKE AIR INLET PIPE
10 - CLAMP
11 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE PIPE
9 - 22
ENGINE
RG
CYLINDER HEAD (Continued)
(19) Remove exhaust manifold heat shield (Fig.
17).
(20) Remove exhaust manifold retaining nuts (Fig.
17).
(21) Slide exhaust manifold and turbocharger off of
exhaust manifold studs (Fig. 17).
(22) Remove cylinder head bolts.
(23) Remove cylinder head assembly from engine
block (Fig. 18).
CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
exhaust manifold and engine cylinder head mating
surfaces. Remove all gasket material and carbon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces.
The minimum cylinder head thickness is 89.95mm
(3.541 in.).
INSTALLATION
CAUTION: Piston protrusion must be measured to
determine cylinder head gasket thickness if one or
more cylinder liners have been replaced (Refer to 9
- ENGINE/CYLINDER HEAD - STANDARD PROCE-
DURE).
NOTE: If cylinder liner(s) have not been removed,
the same thickness head gasket that was removed
can be used.
(1) Clean and inspect gasket mating surfaces.
Fig. 17 EXHAUST MANIFOLD AND
TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY BANJO BOLT
2 - COPPER WASHER
3 - EXHAUST MANIFOLD GASKET
4 - COPPER WASHER
5 - TURBOCHARGER
6 - HEAT SHIELD RETAINING BOLT
7 - ENGINE LIFT HOOK
8 - LIFT HOOK RETAINING BOLT
9 - EXHAUST MANIFOLD RETAINING NUT
10 - TURBOCHARGER RETURN HOSE
11 - EXHAUST MANIFOLD STUD
Fig. 18 CYLINDER HEAD ASSEMBLY
1 - VALVE SPRING
2 - CYLINDER HEAD BOLT
3 - GLOW PLUG
4 - COOLANT TEMPERATURE SENSOR
5 - CYLINDER HEAD ALIGNMENT DOWEL
6 - CYLINDER BLOCK
7 - CYLINDER LINER
8 - ENGINE BLOCK DECK
9 - CYLINDER HEAD GASKET
10 - CYLINDER HEAD
11 - ROCKER ARM AND LIFTER ASSEMBLY
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ENGINE
9 - 23
CYLINDER HEAD (Continued)
(2) Position correct head gasket on engine block.
(3) Place cylinder head on engine block (Fig. 18).
CAUTION: New cylinder head bolts must be used.
(4) Tighten cylinder head bolts following procedure
below.
Cylinder Head Bolt Torquing Procedure
(1) Lubricate cylinder head bolts with engine oil.
(2) Torque bolts to 30N·m in numerical starting
with bolt #1 (Fig. 19).
(3) Tighten all bolts an additional 75°, starting
with bolt #4 then 5-6-7-8-9-10-1-2-3 (Fig. 19).
(4) Tighten all bolts an additional 50° in numerical
order starting with bolt #11 then 12-13-14-15-16-
17-18 (Fig. 19).
(5) Without loosening any bolts tighten all bolts an
additional 75° in the following seguence: 4-5-6-7-8-9-
10-1-2-3-11-12-13-14-15-16-17-18.
(5) Slide exhaust manifold and turbocharger on
exhaust manifold studs (Fig. 17).
(6) Install exhaust manifold retaining nuts. Torque
nuts to 32.4N·m.
(7) Install exhaust manifold heat shield (Fig. 17).
Torque bolts to 27.5N·m.
(8) Install turbocharger outlet to charge air cooler
pipe (Fig. 17).
(9) Install thermostat housing to upper radiator
hose pipe (Fig. 16). Install retaining bolt and torque
to 47.1N·m.
(10) Install coolant recovery pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - INSTALLATION).
(11) Connect glow plug and coolant temperature
sensor electrical connectors.
(12) Install new cylinder head cover/intake mani-
fold gasket.
(13) Install rocker arm and lifter assemblies.Be
sure to put rocker arm and lifter assemblies in
same location as removed.
(14) Install cylinder head cover/intake manifold
(Fig. 15)(Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(15) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(16) Install timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - INSTALLATION).
(17) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(18) Remove crankshaft and both camshaft
locking pins at this time (Refer to 9 - ENGINE/
VALVE TIMING - STANDARD PROCEDURE) .
(19) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(20) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(21) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(22) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(23) Install air cleaner housing assembly.
(24) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(25) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(26) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
INSTALLATION).
(27) Connect negative battery cable.
Fig. 19 CYLINDER HEAD TORQUE SEQUENCE
9 - 24
ENGINE
RG
CYLINDER HEAD (Continued)
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