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Category: Dodge
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Experience:  30 years experience, ase certified,shop owner
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2003 Dodge Intrepid: with a 2.7l..engine cranks but wont start.

Resolved Question:

I have a 2003 Dodge Intrepid with a 2.7l. I bought it not running. The engine cranks but won't start. It sounds like it wants to. The lady said the head gasket was bad. She said she got it checked out. What is the steps to replace the head gaskets?
Submitted: 2 years ago.
Category: Dodge
Expert:  Dodge expert replied 2 years ago.

Welcome to just answer.com. I'm here to help you and your 100% satisfaction is my goal.Welcome to just answer.com. I'm here to help you and your 100% satisfaction is my goal. I would be glad to help you with this but I warn you that this is a pretty involved and time consuming job to do yourself. Here's the procedure as outlined in the Manual.












Removal and
Installation





REMOVAL


  1. Perform fuel
    pressure release
    procedure before attempting any repairs.
  2. Disconnect negative cable from remote jumper terminal.
  3. Drain cooling
    system
    and remove accessory drive belts.
  4. Remove the vibration dampner.
  5. Remove upper and lower intake manifolds.
  6. Remove cylinder head cover and timing
    chain
    cover.



















  1. Remove water outlet connector (Fig. 13).
  2. Rotate crankshaft
    until crankshaft sprocket timing mark aligns with timing mark on oil
    pump
    housing.
  3. Remove primary timing
    chain
    .



















  1. Remove camshaft
    bearing
    caps gradually in REVERSE sequence of installation (10-1) (Fig.
    14).



















  1. Remove camshafts and valvetrain components from cylinder head (Fig. 15).
    Note component locations for re-installation in original locations.
  2. Remove V-Band clamp(s) at exhaust
    manifold
    to catalytic
    converter
    pipe.





NOTE:Do not reuse V-Band clamp.












Cylinder Head Bolts 2.7L












CAUTION:Ensure cylinder head bolts 11-9 (Fig. 16) are removed before
attempting the removal of cylinder head, as damage to cylinder head and/or block
may occur.


  1. Remove cylinder head bolts in reverse sequence of installation (Fig. 16)
    starting with bolts 11-9, then bolts 8-1.
  2. Remove cylinder head(s).
  3. Remove and discard cylinder
    head gasket
    .
  4. Clean cylinder head and block sealing surfaces.

CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the use of aluminum engine
components and multi-layer steel cylinder
head gaskets
.






NOTE:Multi-Layer Steel (MLS) head gaskets require a scratch
free sealing surface.

Remove all gasket material from cylinder head and block. Be careful not to
gouge or scratch the aluminum head sealing surface.

Clean all engine oil
passages.

INSPECTION



  1. Before cleaning, check for leaks, damage and cracks.
  2. Clean cylinder head and oil passages.



















  1. Check cylinder head for flatness (Fig. 17).
  2. Cylinder head must be flat within:


    • Standard dimension = less than0.05 mm (0.002 in.)
    • Service Limit = 0.2 mm (0.008 in.)
    • Grinding Limit = Maximum of 0.2 mm (0.008 in.) is
      permitted.






CAUTION:0.20 mm (0.008 in.) MAX is a combined total dimension
of the stock removal limit from cylinder head and block top surface (Deck)
together.

















INSTALLATION







NOTE:The cylinder head bolts are tightened using a torque plus
angle procedure. The bolts must be examined BEFORE reuse. If the threads are
necked down the bolts must be replaced (Fig. 18)

Necking can be checked by holding a straight edge against the threads. If all
the threads do not contact the scale, the bolt must be replaced (Fig.
18)






CAUTION:When cleaning cylinder head and cylinder block surfaces, DO
NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a
wooden or plastic scraper.


  1. Clean sealing surfaces of cylinder head and block.
  2. Install new head gasket over locating dowels.
  3. Install cylinder head to block, assuring head is properly positioned over
    locating dowels.
  4. Lubricate bolt threads with clean engine oil and install bolts.



















  1. Tighten bolts in sequence shown in (Fig. 19), using the following steps and
    torque values: Step 1: Bolts 1-8 to 48 Nm (35 ft. lbs.)

Step 2: Bolts 1-8 to 75 Nm (55 ft. lbs.)
Step 3: Bolts 1-8 to
75 Nm (55 ft. lbs.)
Step 4: Bolts 1-8 to +90° Turn Do not use
a torque wrench for this step.
Step 5: Bolts 9-11 to 28 Nm (250 in.
lbs.)



  1. Connect catalytic
    converter
    to exhaust
    manifold
    with a new V-Band clamp. Tighten V-Band clamp to 10 Nm (100 in.
    lbs.).



















  1. Install all valvetrain components and camshafts. Tighten camshaft
    bearing
    caps in sequence shown in (Fig. 20)
  2. Install timing
    chain
    and sprockets.
  3. Install water outlet connector (Fig. 13).
  4. Install cylinder head covers.
  5. Install timing
    chain
    cover and crankshaft
    vibration damper.
  6. Install lower and upper intake manifolds.
  7. Install accessory drive belts.
  8. Fill cooling
    system
    .
  9. Connect negative cable to remote jumper
    terminal.
Dodge expert, ASE Cert Technician
Category: Dodge
Satisfied Customers: 10370
Experience: 30 years experience, ase certified,shop owner
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