Dodge Dakota (R1). Manual — part 528
CYLINDER HEAD
DESCRIPTION - CLYINDER HEAD GASKETS
A steel cylinder head gasket is used for all four cyl-
inder heads.
Cylinder head gaskets are available in three thick-
nesses. Identification holes in the right front corner
of the gasket indicate the thickness of the gasket
(Fig. 26).
CAUTION: Piston protrusion must be measured, to
determine cylinder head gasket thickness, if one or
more cylinder wall liners have been replaced.
NOTE:
If
cylinder
wall
liners
have
not
been
removed; the same thickness head gasket removed,
may be used.
REMOVAL
(1) Disconnect the negative battery cable.
WARNING:
DO
NOT
REMOVE
THE
CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE - STANDARD PROCEDURE).
(3) Discharge
the
air
conditioning
system,
if
equipped. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/REFRIGERANT
-
STAN-
DARD PROCEDURE).
(4) If equipped with air conditioning, remove the
A/C lines at the compressor and cap. Refer to Group
24, Heating and Air Conditioning. Remove A/C line
bracket attached to cylinder head cover, and move
A/C lines away from cylinder head.
(5) Remove the air cleaner hose from turbocharger
and breather hose.
(6) Remove the air cleaner assembly and breather
hose.
(7) Remove the generator support bracket.
(8) Remove the upper radiator hose and coolant
recovery hose.
(9) Remove the water manifold and recovery hose.
(10) Disconnect
the
heater
hoses
and
coolant
recover bottle hose.
Fig. 26 Steel Type Cylinder Head Gasket—
identification
HOW TO IDENTIFY GASKET THICKNESS
NO HOLES
1.41 mm
2 HOLES
1.51 mm
1 HOLE
1.61 mm
Fig. 27 Turbocharger
1 - EGR TUBE
2 - EGR VALVE
3 - OIL FEED LINE
4 - OIL DRAIN
5 - TURBO
9a - 30
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
(11) Disconnect the EGR tube from EGR valve.
(12) Remove the EGR valve.
(13) Remove the exhaust heat shield from exhaust
manifold.
(14) Remove the exhaust heat shield from down
pipe.
(15) Remove the exhaust down pipe from turbo-
charger (Fig. 27).
(16) Disconnect the oil feed line from turbocharger.
(17) Disconnect the oil drain line from turbo-
charger.
(18) Remove the Exhaust manifold (Refer to 11 -
EXHAUST
SYSTEM/TURBOCHARGER
SYSTEM/
TURBOCHARGER - REMOVAL).
(19) Remove the Intake manifold. Refer to intake
manifold removal and installation for procedure.
(20) Remove the oil feed line retaining bracket at
rear of #4 cylinder head.
(21) Remove the oil feed line retaining bracket
(Fig. 28).
(22) Remove the oil feed line for rocker arm
assemblies (Fig. 29).
(23) Remove the Crankcase breather hose from
rear of the valve cover.
(24) Remove the injector sensor wire and the glow
plug hot lead.
(25) Remove the fuel lines and fuel filter. Refer to
Group 14, Fuel Systems for procedure.
(26) Remove the injector fuel lines from injectors
to pump.
(27) Remove the fuel injectors with tool VM.1012
(Fig. 30). (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL INJECTOR - REMOVAL).
(28) Remove the engine cylinder head cover.
(29) Remove the rocker retaining nuts (Fig. 31).
(30) Remove the rocker arm assemblies. Place
them on a bench in the same order as removed.
(31) Remove the push rods and place them on a
bench in the same order as removed.
(32) Mark the cylinder head positions.
(33) Remove the engine cylinder head bolts with
special tool VM.1018 and VM.1019.
(34) Remove the engine cylinder head and gasket.
(35) Stuff clean lint free shop towels into the cyl-
inder bores.
Fig. 28 Oil Feed Line Retainer
1 - CYLINDER HEAD OIL SUPPLY LINE RETAINING CLIP
2 - EXHAUST MANIFOLD
3 - CYLINDER HEAD OIL SUPPLY LINE
4 - REAR OF CYLINDER HEADS
5 - CYLINDER HEAD COVER
Fig. 29 Rocker Arm Oil Feed Lines
Fig. 30 Fuel Injector Tool VM.1012B
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 31
CYLINDER HEAD (Continued)
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 (Fig. 32).
Minimum cylinder head thickness 89.95mm (3.541
in.)
CAUTION: If only one cylinder head is found to be
distorted and requires machining, it will also be
necessary
to
machine
the
remaining
cylinders
heads and end plates by a corresponding amount
to maintain correct cylinder alignment.
INSTALLATION
(1) Remove the shop towels from the cylinder
bores. Coat the bores with clean engine oil.
(2) Install cylinder head alignment studs VM.1009.
(3) After determining the correct head gasket
thickness, clean the block and head mating surfaces,
place the engine cylinder head gasket over the align-
ment studs.
(4) Place the engine cylinder head over the align-
ment studs.
CAUTION: New cylinder head bolts should be used.
(5) Tighten the engine cylinder head bolts in
sequence according to the following procedure (Fig.
33):
(a) The threads and underside heads of the bolts
should be lubricated. Use the cylinder head align-
ment studs tool number VM-1009. Position the
heads on the block and secure with the ten large
center bolts (14mm) and spacers (clamps), finger
tight only.
(b) Ensure that the various clamps are installed
correctly and the head gasket remains in it’s
proper position, completely covered. Then, lubricate
and install the eight small bolts (12mm), also fin-
ger tight.
(6) Install the intake and exhaust manifolds with
a new gasket, partially tightening the nuts to a max-
imum of 5 N·m (44 in. lbs.). This will align the heads.
Refer to Group 11, Exhaust System and Turbo-
charger for the proper procedure. Install lift eye and
brake vacuum tube at this time.
(7) Then, tighten the 14mm bolts with special tool
VM.1019 in the following manner:
(8) 1st Phase: Tightening Head Bolts (Fig. 33).
Central bolts (A-L): Tighten all bolts, starting with
bolt H then G-F-E-D-C-B-A-L-I, to 30 N·m. Tighten
all bolts an additional 70°, starting with bolt A and
continuing in alphabetical order. Finally, tighten all
bolts an additional 70°, starting again with bolt A
and continuing in alphabetical order.
(9) Tighten the 12mm bolts in the following man-
ner:
(10) Side bolts (M1-M2): Tighten M1 bolts to 30
N·m, then rotate them 85° (±5). Tighten M2 bolts to
30 N·m, then rotate them 85° (±5).
Fig. 31 Rocker Arm Retaining Nuts
1 - ROCKER ARM ASSEMBLY
2 - ROCKER ARM RETAINING NUTS
3 - ROCKER ARM SPRING PLATE
Fig. 32 Checking Cylinder Head Flatness
9a - 32
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
CYLINDER HEAD (Continued)
NOTE: If vehicle is equipped with A/C do not install
A/C lines to compressor and charge A/C till Phase 2
is complete.
(11) 2nd Phase: After 20 minutes of engine oper-
ation at operating temperature, allow engine to cool
down completely. Then retorque the head bolts as fol-
lows:
(12) Central bolts A-L: Completely back off bolts
one-by-one and then retighten to 30 N·m plus 130°
(±5°). Then proceed in the same way, bolt by bolt, fol-
lowing alphabetical order, as indicated.
(13) Side
bolts
M1-M2:
Without
slackening,
torque bolts M1 then bolts M2 to 90 N·m (66 ft. lbs.).
(14) Torque intake nuts to 32 N·m (24 ft. lbs.) and
exhaust manifolds nuts to 32 N·m (24 ft. lbs.) after
completing the cylinder head torquing procedure.
(15) Install the oil feed lines for the rocker arm
assemblies. Torque oil feed lines to 13 N·m (115 in.
lbs.).
(16) Install the oil feed line retaining bracket at
rear of #4 cylinder head (Fig. 34).
(17) Install the push rods and rocker arm assem-
blies. (Refer to 9 - ENGINE/CYLINDER HEAD/
ROCKER ARMS - INSTALLATION).
(18) Install the cylinder head cover. Torque bolts to
15 N·m (133 in. lbs.).
(19) Connect the crankcase breather hose.
(20) Connect the injector sensor wire and the glow
plug hot lead.
(21) Install the turbocharger oil feed line. Torque
banjo bolts to 27 N·m (20 ft. lbs).
(22) Install the turbocharger oil drain line. Torque
bolts to 11 N·m (97 in. lbs.).
(23) Install the water manifold. Torque bolts to 12
N·m (106 in. lbs.).
(24) Install the generator support bracket.
(25) Raise the vehicle on hoist.
(26) Install the exhaust down pipe to turbocharger,
tighten bolts to 22 N·m (16 ft. lbs.).
(27) Install the exhaust down pipe heat shield.
(28) Install the exhaust heat shield, Tighten bolts
to 11 N·m (8 ft. lbs.).
(29) Install the EGR valve to intake manifold,
tighten bolts to 27 N·m (20 ft. lbs.).
(30) Install the EGR tube to EGR valve, tighten
bolts to 27 N·m (20 ft. lbs.).
(31) Install the lower charge air cooler hose to tur-
bocharger.
(32) Install the air cleaner assembly and hose.
(33) Install the oil breather hose to air cleaner
hose.
(34) Install the upper charge cooler hose to turbo-
charger.
(35) Connect the recover bottle hose to water man-
ifold.
(36) Install the fuel injectors using special tool
VM.1012. (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL INJECTOR - INSTALLATION).
(37) Install the fuel injector lines from the pump
to injectors. Torque nuts to 19 N·m (14 ft. lbs.).
(38) Connect the A/C lines to compressor and
install bracket on cylinder head cover, if equipped
with air conditioning.
Fig. 33 Engine Cylinder Head Bolt Tightening Sequence
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 33
CYLINDER HEAD (Continued)
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