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TSB 09-04-91

New Cylinder Head Cover Gasket, 3.9L, 5.2L, and 5.9L Engines

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Date: June 17, 1991

Models: 1987 - 1991 (AD) - RAM PICKUP

1987 - 1989 (M) DIPLOMAT/GRAM FURY/FIFTH AVENUE
1987 - 1991 (B/AB) RAM VAN/WAGON (RWD)
                    (D/AD) RAM PICKUP/RAM CAB & CHASSIS/RAMCHARGER
                     (RWD, 4WD) POWER RAM CAB & CHASSIS (4WD)
                   (N/AN) DAKOTA/DAKOTA SPORT/DAKOTA CONVERTIBLE./
                     DAKOTA CAB & CHASSIS (RWD, 4WD)

Discussion:

A new cylinder head cover gasket entered engine production in March, 1991. This new gasket is a steel-backboned, silicon-formed design with compression limiters. The new gasket provides improved sealing. In addition the new gasket in most cases will not require replacement when removing the cylinder head cover during engine servicing. Simply wipe the gasket and sealing surface off with a clean cloth and install the gasket in the same position.

When leak diagnosis or engine service requires cylinder head cover gasket replacement, both gaskets should be replaced on vehicles with engines built prior to Engine Date Codes:

3.9L V6 - 0848
5.2L V8 - 0846
5.9L V8 - 0855

Because the new gasket is thicker, new cylinder head cover fasteners will be packaged with the gasket. These new fasteners MUST be used when installing the new gasket on engines with the old style gasket as outlined in the following procedure:

NOTE: THIS NEW GASKET MAY ALSO BE USED ON ALL 1971 TO 1987 DOMESTIC CHRYSLER, DODGE, PLYMOUTH, CARS AND TRUCKS EQUIPPED WITH 5.2L AND 5.9L V8 ENGINES.

Parts Required:

3.9L Engine

2    Cylinder Read Cover Gasket Package    PN 04638617

Package Contains:

1 Gasket   53005658
6 Bolts      6025325

5.2L/5.9L Engine

2 Cylinder Head Cover Gasket Package     PN 04633618

Package Contains:

1 Gasket 53005660
5 Bolts    6034401

Repair Procedure:

This repair involves replacing the cylinder head cover gaskets with revised gaskets.

3.9L V6 ENGINE

1. Remove the cylinder head cover as outlined in the appropriate service manual.

2. Thoroughly clean the cylinder head cover and cylinder head rail (head sealing surface).

3. Check the cylinder head cover for distortion in the area of the fastener holes and flange and straighten as required, using a block of wood and small hammer.

4. Remove the cylinder head cover fastener studs.

NOTE: FAILURE TO REMOVE THE STUDS WILL CAUSE INTERFERENCE WITH THE COMPRESSION LIMITERS IN THE GASKET.

5. Install the cylinder head cover and gasket using the new fasteners, tighten to 95 in. lbs. (10.7 N-m)

5.2L 5.9L VS ENGINES

1. Remove the cylinder head cover as outlined in the appropriate service manual.

2. Thoroughly clean the cylinder head cover and cylinder head rail (head sealing surface).

3. Check the cylinder head cover for distortion in the area of the fastener holes and flange and straighten as required, using a block of wood and small hammer.

4. Install the cylinder head cover and gasket, tighten the new fasteners to 95 in. lbs. (10.7 N-m).

Notes:

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
3.9L Engine
Labor Operation No. 09-35-25-90 B/AB . . . . . . . . . . . 1.2 Hrs.
                                                       D/AD, N/AD . . . . . 1.1 Hrs.
5.2L/5.9L Engine
Labor Operation No. 09-35-25-91 B/AB . . . . . . . . . . .  0.9 Hrs.
                                                       D/AD, N/AN . . . . . 0.8 Hrs.

FAILURE CODE: 65 - Leaks