Chrysler DODGE D150 1993 Service Manual page 658

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5.2L ENGINE 9 - 53
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness ex­
ceeds 0.00075 mm/mm (0.00075 inch/inch) times the
span length in inches in any direction, either replace
head or lightly machine the head surface.
F O R E X A M P L E : A 305 m m (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept­
able.
The cylinder head surface finish should be 1.78-
3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
(1) Apply Perfect Sealant No.5, or equivalent, to
both sides of the gasket (Fig. 5).
Fig. 5 Sealant Location on Cylinder Head Gasket
(2) Position the new cylinder head gaskets onto the
cylinder block.
(3) Position the cylinder heads onto head gaskets
and cylinder block.
(4) Starting at top center, tighten all cylinder head
bolts, in sequence, to 68 N»m (50 ft. lbs.) torque (Fig.
6). Repeat procedure, tighten all cylinder head bolts
to 143 N®m (105 ft. lbs.) torque. Repeat procedure to
confirm t h a t all bolts are at 143 N-m (105 ft. lbs.)
torque.
C A U T I O N : When tightening the rocker arm bolts,
make sure the piston in that cylinder is N O T at
T D C . Contact between the valves and piston could
occur.
(5) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N»m
(21 ft. lbs.) torque.
(6) Place the 4 plastic locator dowels into the holes
in the block Fig. 7).
Fig. 6 Cylinder Head Bolt Tightening Sequence
(7) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, to the four corner joints. An ex­
cessive amount of sealant is not required to ensure a
leak proof seal. However, an excessive amount of
sealant may reduce the effectiveness of the flange
gasket. The sealant should be slightly higher t h a n
the cross-over gaskets, approx. 5 mm (0.2 in).
(8) Install the front and rear cross-over gaskets
onto the dowels (Fig. 7).
FRONT CROSS-OVER GASKET
REAR CROSS-OVER GASKET J9209-99
Fig. 7 Cross-Over Gaskets and Locator Dowels
(9) Install the flange gaskets. Be sure t h a t the ver­
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must
be in position with t h e mating cylinder head gasket
tabs (Fig. 8). The words MANIFOLD SIDE should be
visible on the center of each flange gasket.
(10) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. Use the