Mopar 53021609DD Head-Cylinder

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Lift the head(s) off the engine, ensuring all bolts are removed, and place them on wooden blocks.

Drain the cooling system, then remove the upper and lower intake manifolds.

Coat the head bolt threads with engine oil.

Lift the cylinder head off the engine block with the attached exhaust manifold, and if stuck, gently pry it up at the transmission end beyond the gasket surface.

Lift the head(s) off the engine, ensuring all bolts are removed, and place them on wooden blocks.

Remove the drivebelt, air filter housing, and resonator, then disconnect all wires and vacuum hoses from the intake manifolds and cylinder heads, labeling them for reinstallation.

Position the new gaskets correctly on the dowels in the block.

Carefully place the heads on the block without disturbing the gaskets, coat the head bolt threads with engine oil, and install them in their original locations.

After disconnecting the battery, drain the cooling system, then remove the intake manifold and the exhaust manifolds from the cylinder heads.

Remove the lower intake manifold and the exhaust manifold(s).

To begin the removal process, take care not to disturb the crankshaft alignment marks and remove the primary timing chain and sprockets.

The cylinder head, with the camshaft in place and the exhaust manifold attached, should be carefully lifted off the engine block, and any external components should be removed for thorough cleaning and inspection.

Take off the valve covers, rocker arms, and pushrods.

Lift the cylinder head off the engine block with the camshaft and exhaust manifold in place, prying gently if necessary.

When installing head bolts, applying clean engine oil to M10 bolt threads and hardened washers (if equipped), with the chamfered side of the washers facing the bolt heads, is recommended. For M8 head bolts, thread sealant should be applied to the bolt threads.

After removing the cylinder head, it should be inspected and serviced as necessary. Any damage should be addressed during this phase.

Disconnect the exhaust pipe from the turbocharger, remove the viscous fan and drive assembly, and raise the engine with support or a hoist. Remove the right engine mount through-bolt and the engine mount itself. Disconnect the turbo oil drain fitting and seal the openings. Disconnect the air intake temperature sensor wiring, remove the air filter housing and snorkel, and tape the open turbo port. Disconnect heater hoses, oil supply line, and coolant lines from the turbocharger, sealing the openings. Remove the EGR cooler, exhaust manifold with the turbo attached, fan and shroud assembly, and the drive belt. Lower the alternator, disconnect the upper radiator hose, and label and disconnect all wiring attached to the cylinder head. Remove the engine oil dipstick tube bolt, air intake housing, pump-to-fuel rail line, fuel rail-to-head lines, and fuel line shield. Remove the fuel injectors and rocker housing.

Install new cylinder head bolts and tighten them following the recommended sequence.

Complete the remaining installation steps, including changing the oil and filter, refilling the cooling system, and priming the fuel filter before starting the engine.

The initial steps are to relieve the fuel system pressure and disconnect the battery. Drain the cooling system and remove the drivebelt. Take out the PCV and EVAP system components, as well as the cowl.