How to Replace the Head Gasket in a D Series Dodge Pickup

The Dodge D Series pickups use several engines, depending on which D series truck you have, including the 2.0-liter engine in the D50. You can blow the head gasket on the truck if you let the engine overheat. Once the head gasket is blown, the vehicle will continue to overheat if the gasket is blown at the water jackets. If the gasket is blown at an exhaust valve, it will cause the engine to run poorly, and exhaust gas will leak into the radiator. If it is blown at an intake valve, it will leak water into the oil, causing the oil to have a milky look.

Things You'll Need

• Set of wrenches
• Drain pan
• Shop rags
• Set of line wrenches
• Set of sockets
• Screwdriver
• Tape and marker
• Rubber mallet
• Plastic scraper
• Torque wrench
• Oil filter wrench

Instructions

1. Disconnect the negative battery cable, using the appropriate wrench, then set it aside, ensuring that it does not touch metal. Slide the drain pan under the radiator petcock. Open the petcock and remove the radiator cap, and allow the coolant to drain. Discard the coolant in an appropriate manner.

2. Remove the throttle cable and TV cable from the carburetor, using the screwdriver. Label the vacuum lines on the carburetor using the tape and marker, then remove them, using the screwdriver. Lay shop rags under the fuel lines at the carburetor. Remove the fuel lines from the carburetor using the appropriate line wrench, and unbolt the carburetor from the manifold using the appropriate socket.

3. Unbolt and remove the intake manifold using the appropriate socket. Remove the exhaust manifold using the appropriate socket. Loosen the hose clamps on the upper and lower radiator hoses at the engine and the radiator, and pull the hoses off at the engine and the radiator. Unbolt the radiator from its support brackets, then lift the radiator out of the engine compartment.

4. Remove the engine fan using the appropriate socket. Remove the fan shroud bolts and lift the engine fan and fan shroud out of the engine compartment as an assembly. Label all wires and vacuum hoses on the top of the engine using the tape and marker. Unplug the wiring harness connectors and remove the vacuum lines.

5. Remove the valve covers using the appropriate sockets. If the valve covers "stick," tap them with the rubber mallet to loosen the gasket. Remove the upper timing belt cover using the appropriate sockets.

6. Turn the engine via the crankshaft pulley bolt with the appropriate socket until the timing marks on the crankshaft pulley and the camshaft sprocket line up. If the crankshaft pulley mark lines up, but the camshaft timing marks do not line up, turn the engine over one more revolution, and both marks will line up.

7. Loosen the bolt that holds the upper timing belt sprocket to the camshaft, then carefully remove the bolt and the sprocket from the camshaft while keeping tension on the belt at all times. Lay the sprocket on the pad in the lower timing cover, ensuring that you keep tension on the belt.

8. Look to see that all wiring harness connectors and hoses have been removed from the head. Loosen the head bolts in three steps, following the diagram in the References section below. Once the bolts have been loosened to the point where you can unbolt them the rest of the way by hand, remove them.

9. Rock the head to break it loose. If it will not come loose, tap it with the rubber mallet at the corners. Remove the head from the engine compartment and support it on a wooden block.

10. Position the new head gasket onto the engine. The identifying mark on the gasket should be facing up. Install the head onto the gasket, without moving the head from side to side, because you could knock the gasket out of place. Install the head bolts and turn them in by hand for one or two threads.

11. Tighten the bolts starting with the two middle bolts and working in a crisscross pattern to each end, tightening to 34 foot-pounds of torque. Repeat the pattern and further tighten the bolts to 68 foot-pounds of torque.

12. Reinstall the camshaft sprocket and timing belt, keeping pressure on the timing belt and tighten the bolt to 65 foot-pounds of torque. Reinstall the upper timing belt cover and valve cover. Reinstall the exhaust manifold and intake manifolds, using new gaskets. Reinstall the carburetor. Reconnect the wiring harness connectors and vacuum lines. Reinstall the fan and shroud.

13. Reinstall the radiator and close the petcock. Fill the radiator with the proper mixture of antifreeze. Refer to the owner's manual for the mixture for your area. If you live in an area where it doesn't freeze, you can use 50/50 antifreeze, available at an auto parts store.

14. Slide the drain pan under the oil pan. Remove the oil pan drain bolt and allow the oil to drain. Remove the oil filter using the oil filter wrench. Discard the oil and filter in an appropriate manner. Reinstall the new oil filter and oil drain pan bolt. Fill the engine with the amount and type of oil recommended in your owner's manual.

References

• Auto Zone: Repair Manual for Dodge D Series Pickup: Head Gasket