Dodge Caliber. Manual — part 1072

INSTALLATION

1. Make sure the rubber grommets, for the air cleaner

housing lower pins, are in place when reinstalling
the air cleaner housing. The rubber grommets
mount to the PDC bracket.

2. Push air cleaner housing (1) down while aligning

pins into the grommets.

3. Connect the throttle body air inlet hose (5) to the

air cleaner housing (1).

4. Connect intake air temperature sensor connector

(4).

5. Install fresh air inlet (2) and lock retainers (5).

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CYLINDER HEAD

DESCRIPTION

The cross flow designed, aluminum cylinder head contains dual over-head camshafts with four valves per cylinder.
The valves are arranged in two in-line banks. The intake valves face toward the front of the vehicle. The exhaust
valves face the dash panel. The cylinder head incorporates powdered metal valve guides and seats. The cylinder
head is sealed to the block using a multi-layer steel head gasket and retaining bolts.

Integral oil galleries provide lubrication passages to the variable camshaft timing phasers, camshafts, and valve
mechanisms.

NOTE: Replacement cylinder heads will come complete with valves, seals, springs, retainers, keepers, lash
buckets, and camshafts.

DIAGNOSIS AND TESTING

CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent water
jacket or from an oil passage to the exterior of the engine.

Possible indications of the cylinder head gasket leaking between adjacent cylinders are:

•

Loss of engine power

•

Engine misfiring

•

Poor fuel economy

Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:

•

Engine overheating

•

Loss of coolant

•

Excessive steam (white smoke) emitting from exhaust

•

Coolant foaming

CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cyl-
inder Compression Pressure Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). An engine cylinder head
gasket leaking between adjacent cylinders will result in approximately a 50–70% reduction in compression pressure.

CYLINDER-TO-WATER JACKET LEAKAGE TEST

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP
REMOVED.

VISUAL TEST METHOD

With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat
opens.

If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.

COOLING SYSTEM TESTER METHOD

WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE
PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE
POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).

Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester’s
pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.

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CHEMICAL TEST METHOD

Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent.
Perform test following the procedures supplied with the tool kit.

REMOVAL - CYLINDER HEAD

1. Perform fuel system pressure release procedure before attempting any repairs

2. Remove clean air hose and air cleaner housing (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER

HOUSING - REMOVAL).

3. Disconnect negative cable from battery.

4. Drain cooling system.

5. Remove engine cover.

6. Remove coolant recovery bottle.

7. Remove power steering pump and reposition.

8. Remove windshield washer bottle.

9. Disconnect breather hose.

10. Disconnect PCV hose.

11. Disconnect ignition coil electrical connectors.

12. Remove valve cover.

13. Raise vehicle.

14. Remove right splash shield.

15. Set engine to TDC.

16. Remove accessory drive belts (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).

17. Remove lower A/C compressor bolts if equiped.

18. Remove lower A/C compressor mount.

19. Remove accessory drive belt lower idler pulley.

20. Remove crankshaft and water pump pulleys.

21. Remove right side engine mount bracket lower bolt.

22. Remove timing chain cover lower bolts.

23. Disconnect oxygen sensor electrical connectors.

24. Remove exhaust pipe at manaverter (AWD).

25. Remove manaverter support bracket retaining bolts (AWD).

26. Lower vehicle.

27. Remove power steering pump and set aside.

28. Support engine with suitable jack.

29. Remove right engine mount.

30. Remove accessory drive upper idler pulley.

31. Remove right upper engine mount bracket.

32. Remove accessory drive belt tensioner.

33. Remove upper timing chain cover retaining bolts.

34. Remove timing chain cover.

35. Remove timing chain tensioner.

36. Remove timing chain.

37. Remove timing chain guides.

38. Disconnect fuel line at the fuel rail.

39. Disconnect fuel injector electrical connectors.

40. Disconnect top engine electrical connectors and reposition harness.

41. Remove fuel rail.

42. Remove lower intake manifold support bracket retaining bolt.

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43. Disconnect electronic throttle control electrical connector.

44. Disconnect map sensor electrical connector.

45. Disconnect vacuum lines at intake.

46. Remove intake manifold retaining bolts.

47. Remove upper radiator hose retaining bolts.

48. Remove intake manifold.

49. Remove coolant outlet manifold and set aside.

50. Remove ground strap at right rear of cylinder head.

51. Remove oxygen sensor from maniverter (AWD).

52. Remove maniverter heat shields (AWD).

53. Remove maniverter retaining bolts (AWD).

54. Remove maniverter from cylinder head and reposition out of the way (AWD).

55. Remove camshafts (Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).

NOTE: All of the cylinder head bolts have captured
washersEXCEPTthe front two (1).

56. Remove cylinder head bolts.

57. Remove cylinder head from engine block.

58. Inspect and clean cylinder head and block sealing

surfaces. Refer to Cleaning and Inspection in this
section for procedures.

NOTE: Ensure cylinder head bolt holes in the
block are clean, dry (free of residual oil or cool-
ant), and threads are not damaged.

CLEANING

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of alumi-
num engine components and multi-layer steel cylinder head gaskets.

NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Remove all gasket material from cylinder head and block (Refer to 9 - ENGINE - STANDARD PROCEDURE). Be
careful not to gouge or scratch the aluminum head sealing surface.

Clean all engine oil passages.

INSPECTION

NOTE: Replacement cylinder heads will come complete with valves, seals, springs, retainers, keepers, lash
buckets, and camshafts.

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