Dodge dakota 2002 Service Manual page 1621

9 - 372 ENGINE 8.0L
CYLINDER HEAD (Continued)
fuel line (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/QUICK CONNECT FITTING - STANDARD
PROCEDURE).
(9) Disconnect accelerator
equipped, the speed control and transmission kick-
down cables.
(10) Remove coil pack and bracket (Fig. 8).
Fig. 8 Coil Pack and Bracket
1 - COIL PACKS AND BRACKET
2 - MOUNTING BOLTS (4)
(11) Disconnect the coil wires.
(12) Disconnect heat indicator sending unit wire.
(13) Disconnect heater hoses and bypass hose.
(14) Remove upper intake manifold and throttle
body as an assembly (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - REMOVAL).
(15) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(16) Remove the EGR tube. Discard the gasket, for
right side only.
(17) Remove lower intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
REMOVAL). Discard the flange side gaskets and the
front and rear cross-over gaskets.
(18) Disconnect exhaust pipe from exhaust mani-
fold.
(19) Remove exhaust manifolds and gaskets (Refer
to 9 - ENGINE/MANIFOLDS/EXHAUST MANIFOLD
- REMOVAL).
(20) Remove rocker arm assemblies and push rods
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - REMOVAL). Identify to
ensure installation in original locations.
linkage and if so
MANIFOLD -
(21) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(22) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads. Be sure material does not fall into the lifters
and surrounding valley.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
Clean the exhaust manifold to cylinder head mat-
ing areas.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. The out-of-flatness
specifications are 0.0007 mm/mm (0.0004 inch/inch),
0.127 mm/152 mm (0.005 inch/6 inches) any direction
or 0.254 mm (0.010 inch) overall across head. If
exceeded, either replace head or lightly machine the
head surface.
The cylinder head
1.78-4.57 microns (15-80 microinches).
Inspect push rods. Replace worn or bent rods.
Inspect rocker arms. Replace if worn or scored.
INSTALLATION
(1) Position the new cylinder head gaskets onto
the cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(3) Tighten the cylinder head bolts in two steps
(Fig. 9):
• Step 1—Tighten all cylinder head bolts, in
sequence, to 58 N·m (43 ft. lbs.) torque.
• Step 2—Tighten all cylinder head bolts, in
sequence, to 143 N·m (105 ft. lbs.) torque.
•
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
Fig. 9 Cylinder Head Bolt Tightening Sequence
surface finish should
DR
be