Dodge Viper SRT-10 (ZB). Manual — part 172

• MAP sensor

• Idle Speed Control

• Throttle Position Sensor

• Right cylinder head fuel injectors
(10) Install air cleaner housing assembly, connect

throttle body air inlet hose and connect the Intake
Air Temperature Sensor (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM - INSTALLATION).

(11) Install the wiper motor cowl screen
(12) Install the wiper arms.
(13) Connect negative battery cable. Install battery

cover. Close trunk lid.

(14) With the DRB III

t Scan Tool, use the ASD

Fuel System Test to pressurize fuel system to check
for leaks.

CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.

EXHAUST MANIFOLD

REMOVAL

NOTE: Care must be taken to protect the cylinder
head covers powder coating from scrapes and
abrasions. This procedure covers either the left or
right exhaust manifold.

(1) Open trunk lid. Remove battery cover. Discon-

nect negative battery cable.

(2) Remove left or right side cylinder head covers

(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).

(3) Raise vehicle on hoist.
(4) Loosen and remove V-Band clamp from exhaust

pipe to exhaust manifold connection.

NOTE: Do not reuse V-Band clamp.

(5) Slide exhaust pipe off of the exhaust manifold.
(6) Disconnect upstream oxygen sensor electrical

connector.

(7) Lower vehicle.
(8) Remove manifold heat shield from exhaust

manifolds (Fig. 31).

(9) Note location of exhaust manifold studs and

bolts. Remove studs and bolts attaching manifold to
cylinder head and remove manifold (Fig. 31).

INSPECTION

Inspect exhaust manifolds for damage or cracks.

Check for distortion of the cylinder head mounting
surfaces with a straightedge and feeler gauge (Fig.
32).

Fig. 31 Exhaust Manifold/Gasket/Heat Shield

1 - GASKET
2 - EXHAUST MANIFOLD
3 - STUD AND WASHER
4 - HEAT SHIELD NUT
5 - HEAT SHIELD
6 - BOLT AND WASHER

Fig. 32 Checking Exhaust Manifold Mounting

Surface - Typical

9 - 30

ENGINE

ZB

INTAKE MANIFOLD (Continued)

INSTALLATION

NOTE: Care must be taken to protect the cylinder
head covers powder coating from scrapes and
abrasions. This procedure covers either the left or
right exhaust manifold.

(1) Install new gasket and install exhaust mani-

fold (Fig. 31). Tighten attaching fasteners to 23 N·m
(200 in. lbs.).

(2) Install manifold heat shield and tighten attach-

ing fasteners to 6 N·m (50 in. lbs.) (Fig. 31).

(3) Raise vehicle on hoist.
(4) Connect exhaust pipe to manifold and install

NEW V-Band clamp. Tighten clamp to 11 N·m (100
in. lbs.).

(5) Connect upstream oxygen sensor electrical con-

nector.

(6) Lower vehicle.
(7) Install left or right side cylinder head covers

(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - INSTALLATION).

(8) Connect negative battery cable. Install battery

cover. Close trunk lid.

CYLINDER HEAD(S)

REMOVAL - CYLINDER HEAD(S)

NOTE: Care must be taken to protect the intake
manifold and cylinder head covers powder coating
from scrapes and abrasions. This procedure covers
either the left or right cylinder head.

The aluminum alloy cylinder head shown in (Fig.

33) is held in place by 12,

1

⁄

2

inch bolts and 8,

1

⁄

4

inch

bolts.

(1) Release the fuel pressure (Refer to 14 - FUEL

SYSTEM/FUEL DELIVERY - STANDARD PROCE-
DURE).

(2) Open trunk lid. Remove battery cover. Discon-

nect negative battery cable.

(3) Remove the air cleaner housing (Refer to 9 -

ENGINE/AIR

INTAKE

SYSTEM/AIR

CLEANER

HOUSING - REMOVAL).

(4) Drain the cooling system (Refer to 7 - COOL-

ING/ENGINE - STANDARD PROCEDURE - DRAIN-
ING COOLING SYSTEM).

(5) Raise and support the vehicle (Refer to LUBRI-

CATION & MAINTENANCE/HOISTING - STAN-
DARD PROCEDURE).

(6) Loosen and remove the V-band clamp from the

exhaust pipe to exhaust manifold connection.

Fig. 33 Cylinder Head and Gasket

1 - HEADGASKET
2 - PUSH ROD
3 - ROCKER ARM

4 - CYLINDER HEAD TAPPET GALLERY BOLT (1/4-20)
5 - CYLINDER HEAD BOLT (1/2-13)
6 - CYLINDER HEAD

ZB

ENGINE

9 - 31

EXHAUST MANIFOLD (Continued)

NOTE: Do not reuse V-Band clamp.

(7) Lower the vehicle.
(8) Remove intake manifold (Refer to 9 - ENGINE/

MANIFOLDS/INTAKE MANIFOLD - REMOVAL).

(9) Disconnect the spark plug wires by pulling on

the boot straight out in line with the spark plug. Dis-
lodge spark plug retainers from the cylinder head
cover studs. reposition the spark plug wires.

(10) Disconnect the oil level indicator tube and set

aside.

(11) Disconnect CCV hoses from cylinder head covers.
(12) Remove the cylinder head covers (Refer to 9 -

ENGINE/CYLINDER

HEAD/ROCKER

ARMS

-

REMOVAL).

(13) Remove exhaust manifold heat shields.
(14) Remove exhaust manifold(s) and gasket(s)

(Refer

to

9

-

ENGINE/MANIFOLDS/EXHAUST

MANIFOLD - REMOVAL).

NOTE: If rocker arms and push rods are to be
reused, identify each component to ensure installa-
tion in original locations.

(15) Remove the rocker arm and pedestal assem-

blies.

(16) Remove push rods (Fig. 33).
(17) Remove the 12 head bolts and 8 cylinder head

tappet gallery bolts from cylinder head(s) (Fig. 33).

(18) Remove cylinder head(s) and gasket(s).

CLEANING / INSPECTION

(1) Before cleaning, check for leaks, damage and

cracks.

(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 34).
(4) Inspect all surfaces with a straightedge (2) if

there is any reason to suspect leakage. If out-of-flat-
ness exceeds 0.019 mm (0.00075 in.) times the span
length in inches in any direction, either replace head
or lightly machine the head surface. As an example,
if a 12.0 inch span is 1.0 mm (0.004 in.) out-of-flat,
allowable is 12 x 0.019 mm (0.00075 in.) equals 0.22
mm (0.009 in.). This amount of out-of-flat is accept-
able. *Maximum of 0.2 mm (0.008 in.) for grinding is
permitted.

CAUTION: This is a combined total dimension of
stock removal from cylinder head surface.

INSTALLATION - CYLINDER HEAD(S)

NOTE: This procedure covers either the left or right
cylinder head.

(1) Clean all surfaces of engine block and cylinder

heads (Refer to 9 - ENGINE - STANDARD PROCE-
DURE - ENGINE GASKET SURFACE PREPARA-
TION).

CAUTION: Remove all gasket material from cylinder
head and block using a plastic scraper only. DO
NOT use a metal scraper, as damage to sealing sur-
face may occur.

NOTE: A multi-layer steel head gasket is used.

(2) Install new gasket(s) on the engine block.

Assure all coolant passages and bolt holes align prop-
erly. (Fig. 35).

Fig. 34 Checking Cylinder Head for Warpage

1 - FEELER GAUGE
2 - STRAIGHT EDGE

Fig. 35 Cylinder Head Gasket Installation

9 - 32

ENGINE

ZB

CYLINDER HEAD(S) (Continued)

CAUTION: Cylinder head bolts are coated, DO NOT
oil.

(3) Install cylinder head(s) over dowel pins. Install

cylinder head bolts 1–12. Tighten cylinder head bolts
1–12 in the sequence shown in (Fig. 36) using a two
step torque sequence:

(a) First to 47 N·m (35 ft. lbs.).
(b) Second to 122 N·m (90 ft. lbs.).

(4) After cylinder head bolts 1–12 have been tight-

ened to specifications, install and tighten cylinder
head tappet gallery bolts A–H in sequence shown in
(Fig. 36) to 11 N·m (95 in. lbs.).

(5) Inspect the push rods. Replace worn or bent

push rods as necessary.

(6) Install push rods. Install rocker arms and ped-

estal assemblies into their original positions. Ensure
push rods are seated properly under each rocker
arm. Tighten rocker arm bolts to 35 N·m (26 ft. lbs.)
(Fig. 33).

(7) Install exhaust manifold(s) and gasket(s) (Refer

to 9 - ENGINE/MANIFOLDS/EXHAUST MANIFOLD
- INSTALLATION).

(8) Install exhaust manifold heat shields.
(9) Install cylinder head covers (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - INSTALLATION).

(10) Position and install the oil level indicator

tube. Tighten fastener to 11N·m (95 in. lbs.).

(11) Connect CCV hoses to cylinder head covers.
(12) Install the spark plug wires and plug wire

retainers.

(13) Install intake manifold (Refer to 9 - ENGINE/

MANIFOLDS/INTAKE MANIFOLD - INSTALLA-
TION).

(14) Raise and support the vehicle.
(15) Connect the exhaust system to the exhaust

manifold using new V-Band clamps.

(16) Drain the engine oil.
(17) Lower the vehicle.
(18) Fill engine oil to the proper level (Refer to

LUBRICATION & MAINTENANCE/FLUID TYPES -

DESCRIPTION), (Refer to LUBRICATION & MAIN-
TENANCE/FLUID TYPES - SPECIFICATIONS).

(19) Fill the cooling system (Refer to 7 - COOL-

ING/ENGINE - STANDARD PROCEDURE - FILL-
ING COOLING SYSTEM).

(20) Connect negative battery cable. Install battery

cover. Close trunk lid.

(21) Install the air cleaner assembly.
(22) Start engine and inspect for leaks.

CYLINDER HEAD COVER(S)

REMOVAL

LEFT CYLINDER HEAD COVER

NOTE: Care must be taken to protect the cylinder
head cover powder coating from scrapes and abra-
sions.

(1) Disconnect CCV hose from cylinder head cover.
(2) Disconnect left side spark plug wires by pulling

on the boot straight out in line with plug. Dislodge
spark plug wire retainers from cylinder head cover
studs. Reposition spark plug wires aside.

(3) Disconnect the power brake booster vacuum

hose at the intake manifold and set aside.

(4) Remove the oil level indicator tube fastener

and position tube aside.

NOTE: For reassembly purposes, identify location
of cylinder head cover attaching studs and bolts.

(5) Remove cylinder head cover fasteners. Remove

cylinder head cover from engine (Fig. 37).

RIGHT CYLINDER HEAD COVER

NOTE: Care must be taken to protect the cylinder
head cover powder coating from scrapes and abra-
sions.

(1) Disconnect CCV hose from cylinder head cover.
(2) Disconnect right side spark plug wires by pull-

ing on the boot straight out in line with plug. Dis-
lodge spark plug wire retainers from cylinder head
cover studs. Reposition spark plug wires aside.

NOTE: For reassembly purposes, identify location
of cylinder head cover attaching studs and bolts.

(3) Remove cylinder head cover fasteners.

Fig. 36 Cylinder Head Bolt Tightening Sequence

ZB

ENGINE

9 - 33

CYLINDER HEAD(S) (Continued)