(NOTE: An alternate to this is to use the stock location on the intake manifold, although the timing belt may rub against this area.)
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| <<BACK | |||||||||||||||||||||||||||||||||||||||||||||
| <<HOME>> | |||||||||||||||||||||||||||||||||||||||||||||
| CYLINDER HEAD | |||||||||||||||||||||||||||||||||||||||||||||
| Step 2: Cylinder Head Preparation | |||||||||||||||||||||||||||||||||||||||||||||
| How to prepare a 2.0/2.4L DOHC cylinder head to work on a 2.2/2.5L short block. | |||||||||||||||||||||||||||||||||||||||||||||
| Items needed: | |||||||||||||||||||||||||||||||||||||||||||||
| Neon/Stratus etc 2.0/2.4L DOHC cylinder Head (complete) | 3 - .550" aluminum plugs (1/2' long) | ||||||||||||||||||||||||||||||||||||||||||||
| 1 - Aeroquip (-8AN to 3/8NPT straight) or similar | Loctite 620 (sleeve retainer) | ||||||||||||||||||||||||||||||||||||||||||||
| 1 - Aeroquip (-12AN to 1/2NPT straight) or similiar | 1 - Aeroquip (-4AN to 1/8NPT 90 deg) or similiar | ||||||||||||||||||||||||||||||||||||||||||||
| 1 - Aluminum 3/8NPT hex head plug | MOPAR spray gasket sealant p/n 04318035 | ||||||||||||||||||||||||||||||||||||||||||||
| 10 Mopar Head Bolts - p/n 6503559 (short Neon head bolts). These will need have about 1/2" cut off them. | |||||||||||||||||||||||||||||||||||||||||||||
| NOTE: Cylinder head bolt torque sequence radiates from the center 2 bolts, in a clockwise-spiral pattern, so that the 4th cyl. bolts are tightened last (ie 9 &10 / 10 total). | |||||||||||||||||||||||||||||||||||||||||||||
| 2.1 Plug the three large oil return passages on the back of the cylinder head using the 3 - .550" aluminum plugs. Ensure that loctite is used to keep the plugs in place. | |||||||||||||||||||||||||||||||||||||||||||||
| 2.2 Leave the one crankcase equalization passage in the head unplugged. This will mate with the hole drilled in the block (step 1.7) This will be one of the ways pressure is removed from the bottom end of the short block. | |||||||||||||||||||||||||||||||||||||||||||||
| 2.3 A place for the thermostat and housing needs to be machined on the drivers side of the cylinder head. The large plug on the side of the head will be used as the inlet, so this can be removed. Have the area around this machined flat. Drill and tap two holes that correspond to the thermostat housing. Place studs in these holes (using red 262 loctite). (NOTE: An alternate to this is to use the stock location on the intake manifold, although the timing belt may rub against this area.) |
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| 2.3 Chose a spot on the driver side of the cylinder head to drill a hole for oil drain-back - (area right by the upper EGR bolt hole works well.) Be careful in choosing this spot, as it cannot enter a cooling passage! Drill and tap it for 1/2" NPT and place the -12AN fitting into this hole. Make sure to use teflon tape on this fitting or you will have oil leaking on the driveway. | |||||||||||||||||||||||||||||||||||||||||||||
| 2.4 Using a 3/8 NPT tap, thread the EGR hole and place a 3/8 NPT aluminum hex plug in it. | |||||||||||||||||||||||||||||||||||||||||||||
| 2.5 On the back drivers side of the head there will be either two screw-in plugs or two press in plugs. If you have screw in plugs this will be easy. These holes go directly into the oiling passages in the cylinder head and will be used to feed oil from the oil distribution block on the short block into the cylinder head. So, remove one plug and insert the 1/8" pipe to flare fitting and move on. If you have a non-threaded plug, then a plug fitting with a 1/8" NPT threaded hole will have to be fabricated and pressed in. | |||||||||||||||||||||||||||||||||||||||||||||
| 2.5 Drill and tap a 3/8 NPT hole beside the thermostat housing for the coolant feed for the turbo. | |||||||||||||||||||||||||||||||||||||||||||||
| 2.6 Place MLS gasket on the block followed by the cylinder head. Torque bolts in sequence to proper specification *NOTE: When using all short bolts on the 2.2/2.5L, torque specs are 50ft/lbs + 1/4 turn for ALL bolts* | |||||||||||||||||||||||||||||||||||||||||||||
