Repair 7

How to Replace the Head Gasket on a 97 Plymouth Voyager

The cylinder head gasket on the Plymouth Voyager seals the gap between the cylinder head and the engine block. It prevents the oil from mixing with the engine coolant, and helps to form proper seal for efficient combustion. The head gasket fails when it is overheated or worn. To replace the head gasket you need to remove the cylinder head first.

Instructions

1

Remove the valve covers and the air cleaner assembly. Disconnect the battery ground cable and relocate the spark plug wires. Unplug the vacuum connections. Remove rocker cover screws and remove the cover.

2

Remove camshaft sprockets. Check auto lash adjuster function. Check auto adjusters for free play by inserting a small wire through the air bleed hole in the rocker arm and very lightly push the auto adjuster ball check down. While lightly holding the check ball down move the rocker arm up and down to check for free play. If there is no play replace the adjuster.

3

Remove the distributor extension and camshaft bearings. When removing camshaft bearing caps do not unscrew the bolts from the bearing caps. Remove the rocker arms, rocker shafts and bearing cap as an assembly.

4

Inspect the camshafts along with camshaft bearing journals for damage and binding. If journals are binding, also check the cylinder head for damage. Also check cylinder head oil holes for clogging.

5

Remove the intake and the exhaust manifolds. Unscrew the cylinder head bolts and remove the cylinder head. Examine the cylinder head. Before cleaning, check for leaks, damage and cracks. Check the cylinder head for flatness. Cylinder head must be flat within or less than .002 inches. Remove the old cylinder head gasket.

6

Position the new cylinder head gasket on the block, over locating dowels. Install the cylinder head on the dowels. Fit the 10 mm Allen Hex head bolts with washers. Tighten the cylinder head bolts. When tightening the cylinder head bolts, tighten gradually, working in two or three steps and finally tighten to specified torque of 80 foot pounds.

7

Install the camshafts. Lubricate camshaft journals and cams with engine oil and install camshaft on cylinder head. Reassemble the rocker arms. Align the camshaft bearing caps with arrows depending on the cylinder bank. Install the rocker shafts into bearing cap. Note that the machined portion of the rocker shaft should be facing down.

8

Insert attaching bolts to retain assembly. Install the rocker arm shaft assembly. Apply Mopar Silicone Rubber Adhesive Sealant at bearing cap ends. Install the rocker arm shaft assembly making sure that the arrow mark on the bearing cap and the arrow mark on the cylinder head are in the same direction. Tighten bearing cap to 85 inch pounds and then with additional 180 inch pounds. Install the intake and exhaust manifolds. Install distributor drive adaptor assembly. Install the valve covers the air cleaner assembly. Connect the ground battery cable and the spark plug wires.