Head Gasket - Single

Complete procedure for replacing a single cylinder head gasket on the 2005 Dodge Viper 8.3L V10 engine, including removal of intake manifold, exhaust manifold, valve cover, rocker assembly, and head components.

Warnings

Tools required

Parts

• Cylinder head gasket (single) × 1 — Use OEM specification
• Cylinder head bolts (TTY) × 1 — OEM replacement set - do not reuse
• Valve cover gasket × 1 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Exhaust manifold gasket(s) × 1 — Use OEM specification
• Coolant (Zerex G-05 HOAT) × 1 — 50/50 premix
• Engine oil and filter × 1 — 0W-40 full synthetic
• Anti-seize compound × 1 — High-temperature rated

Fluids

• Zerex G-05 HOAT 50/50 — 19 qt
• 0W-40 full synthetic — 11 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Disconnect negative battery cable and secure away from terminal.
3. Allow engine to cool completely (minimum 3 hours after operation).
4. Remove engine cover panels if equipped.
5. Relieve fuel system pressure by removing fuel pump relay and cranking engine until it stalls.
6. Position coolant drain pan under radiator and drain cooling system completely via radiator petcock and block drains.
7. Remove air intake assembly and air filter housing for access.
8. Label and photograph all electrical connectors, vacuum lines, and hose routing before disconnection.

Procedure

1. 1

   Drain fluids and remove upper engine components
   With cooling system already drained, proceed to drain engine oil. Remove oil drain plug and allow oil to drain completely into drain pan. Remove upper radiator hose and heater hoses from the affected cylinder head side. Disconnect all electrical connectors to components on the affected head including injector harness, temperature sensors, and ignition coil connectors. Remove ignition coils and spark plugs from the cylinders on the affected head. Tag each spark plug with cylinder number for inspection.
2. 2

   Remove intake manifold
   Disconnect throttle body connections, MAP sensor, and all vacuum lines from intake manifold. Remove fuel rail assembly with injectors as a unit (relieve any residual pressure first). Disconnect PCV hoses and breather tubes. Remove intake manifold mounting bolts in reverse of tightening sequence (work from outer bolts toward center). Carefully lift intake manifold away from heads - the manifold spans both cylinder banks. Inspect intake ports and manifold mating surfaces for damage.
   Torque spec

   Intake Manifold Bolt25 Nm (18 lb-ft)
3. 3

   Remove valve cover from affected head
   Disconnect any remaining breather hoses or electrical connectors attached to valve cover. Remove valve cover mounting bolts (typically 8 bolts around perimeter). Carefully break valve cover seal using light taps with rubber mallet if necessary - do not pry against sealing surface. Lift valve cover straight up to avoid damaging gasket surface. Inspect valve train for obvious wear or damage.
4. 4

   Remove exhaust manifold from affected head
   Spray exhaust manifold fasteners with penetrating oil and allow to soak for 15-30 minutes. Support exhaust system with jack or stands to prevent strain on remaining connection. Remove exhaust manifold heat shields if equipped. Remove exhaust manifold mounting nuts working from center outward to prevent warping. Disconnect exhaust manifold from exhaust pipe connection at collector. Remove exhaust manifold and gasket. Inspect manifold for cracks, especially near ports.
   Torque spec

   Exhaust Manifold Nuts25 Nm (18 lb-ft)
5. 5

   Remove rocker arm assembly and pushrods
   Using organized storage (labeled containers or pushrod holder), prepare to maintain component positions. Loosen rocker arm shaft mounting bolts evenly in multiple passes from outer bolts toward center to prevent shaft distortion. Remove rocker shaft assembly as a unit. Carefully remove each pushrod, maintaining exact order and orientation (mark intake vs exhaust if not obvious). Inspect pushrod tips for wear and roll each on flat surface to check for bending. Store pushrods in numbered holder corresponding to cylinder and valve position. Check rocker arm bearing surfaces and shaft for scoring.
6. 6

   Disconnect remaining head components and accessories
   Remove any brackets, ground straps, or accessory mounting points attached to the cylinder head (alternator bracket, A/C compressor bracket, etc. depending on which head is being serviced). Disconnect coolant temperature sensor and any remaining sensors. Ensure all hoses, wires, and mechanical connections to the head are removed. Double-check that no fasteners or connections will interfere with head removal.
7. 7

   Remove cylinder head bolts
   Mark or photograph cylinder head bolt tightening sequence for reference (typically starts at center and works outward in a spiral pattern). Loosen cylinder head bolts in reverse of tightening sequence, working in multiple passes (1/4 turn each pass) to prevent head warping. Remove all cylinder head bolts (VERIFY exact count per head against factory service manual) and store separately from other hardware - these MUST NOT be reused. Inspect bolt holes for coolant or oil intrusion. If fluid is present, clean and dry thoroughly before installation.
   Torque spec

   Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
8. 8

   Remove cylinder head
   Check that all fasteners and connections are removed. Gently rock cylinder head side-to-side to break gasket seal - do not pry between head and block sealing surfaces. If head is stuck, tap gently with soft mallet on casting bosses only. Lift cylinder head straight up - it will be heavy (approximately 50-70 lbs). Place head gasket-side-up on clean padded surface. Remove old head gasket from block deck surface.
9. 9

   Clean and inspect mating surfaces
   Using plastic scraper (never metal), carefully remove all old gasket material from cylinder block deck surface and head mating surface. Clean surfaces with brake cleaner or degreaser and lint-free rags. Vacuum any debris from cylinder bores, bolt holes, and coolant passages - do not allow debris to enter oil passages or cylinders. Inspect block deck surface with straight edge in multiple directions - check for warping using feeler gauges (maximum warp typically 0.003 inch, consult service manual). Inspect head surface similarly. Check cylinder head for cracks using dye penetrant method or pressure testing if available. Chase cylinder head bolt threads in block using appropriate tap or thread chaser. Blow out bolt holes with compressed air. Check that bolt holes are dry - coolant or oil in bolt holes will prevent proper torque.
10. 10

    Install new head gasket and position cylinder head
    Verify block deck surface is completely clean and dry. Install new head gasket on block - note orientation marks (TOP, FRONT, or bank identification markings). Gasket should fit over dowel pins if equipped. Do not use sealant on head gasket unless specifically required by manufacturer. Carefully position cylinder head onto block, aligning with dowel pins and gasket. Lower head straight down without sliding to avoid gasket displacement.
11. 11

    Install and torque cylinder head bolts
    Install all NEW cylinder head bolts finger-tight, ensuring they thread smoothly without cross-threading. Follow the proper tightening sequence (typically center-out spiral pattern). Torque cylinder head bolts per the 2005 Viper 8.3L FSM specification and sequence (VERIFY against factory service manual before proceeding — do not use generic values). Typical Viper procedure is a multi-step torque plus angle sequence; confirm exact ft-lbs and angle degrees from Mopar documentation. Verify all bolts have been torqued through all four steps. Mark bolts with paint pen after final step to confirm completion.
    Torque spec

    Cylinder Head Bolts - Step 140 Nm (30 lb-ft)

    Cylinder Head Bolts - Step 280 Nm (59 lb-ft)

    Cylinder Head Bolts - Step 30 Nm (0 lb-ft) + 90°

    Cylinder Head Bolts - Step 40 Nm (0 lb-ft) + 90°
12. 12

    Install pushrods and rocker arm assembly
    Apply assembly lube or engine oil to pushrod tips. Install each pushrod in its original position, ensuring lower end properly seats in lifter cup - rotate pushrod while pushing down to confirm seating. Verify all pushrods are in correct positions (intake vs exhaust for each cylinder). Apply assembly lube to rocker arm shaft bearings and rocker arm contact surfaces. Position rocker arm assembly over pushrods, ensuring each rocker arm properly engages its corresponding pushrod and valve stem tip. Install rocker shaft mounting bolts and tighten evenly in multiple passes from center outward to prevent shaft binding. Torque rocker shaft bolts to the FSM-specified value (VERIFY against factory service manual). Manually rotate engine two complete revolutions using crankshaft bolt to verify valve train operation and proper valve timing - check for binding or interference.
13. 13

    Install exhaust manifold
    Clean exhaust manifold mating surface on cylinder head. Install new exhaust manifold gasket (do not reuse old gasket). Apply anti-seize compound to exhaust manifold stud threads. Position exhaust manifold and install mounting nuts finger-tight. Torque exhaust manifold nuts to the FSM-specified value (VERIFY against factory service manual) working from center outward in a cross pattern. Reconnect exhaust manifold to exhaust pipe at collector - use new gasket and hardware. Install heat shields if equipped.
    Torque spec

    Exhaust Manifold Nuts25 Nm (18 lb-ft)
14. 14

    Install valve cover
    Clean valve cover mating surface on cylinder head - ensure completely dry and free of oil. Install new valve cover gasket in valve cover groove or on head surface per gasket design. Position valve cover carefully to avoid disturbing gasket. Install valve cover bolts and tighten in a cross pattern from center outward - do not overtighque (typically 90-105 in-lbs). Reconnect any breather hoses or electrical connections to valve cover.
15. 15

    Install intake manifold and remaining components
    Install new intake manifold gaskets on both cylinder heads. Carefully lower intake manifold into position, ensuring gaskets remain properly seated. Install intake manifold mounting bolts finger-tight. Torque intake manifold bolts to the FSM-specified value and sequence (VERIFY against factory service manual). Reinstall fuel rail and injector assembly. Reconnect all vacuum lines, PCV hoses, throttle body connections, and electrical connectors. Install new spark plugs torqued to specification (install dry unless the plug manufacturer or FSM specifically calls for anti-seize on aluminum heads). Install ignition coils and secure electrical connections. Reinstall any brackets, accessories, or ground straps removed during disassembly. Reconnect upper radiator hose and heater hoses with new clamps. Install air intake assembly.
    Torque spec

    Intake Manifold Bolt25 Nm (18 lb-ft)
16. 16

    Refill fluids and final preparation
    Install new oil filter and torque oil drain plug to specification. Fill engine with 11 quarts of 0W-40 full synthetic oil. Close radiator drain and block drains. Fill cooling system with 19 quarts Zerex G-05 HOAT 50/50 coolant - fill radiator and overflow reservoir. Leave radiator cap off initially. Reinstall fuel pump relay. Reconnect negative battery cable. Perform final visual inspection of all connections, hoses, and fasteners.

Reassembly

1. All reassembly steps are integrated into the main procedure steps 10-16.
2. Ensure all torque specifications are followed exactly, particularly the four-step cylinder head bolt procedure.
3. Do not substitute or reuse TTY cylinder head bolts under any circumstances.
4. Verify proper pushrod and rocker arm positioning before rotating engine.
5. Use only new gaskets - never reuse head gasket, intake gaskets, exhaust gaskets, or valve cover gasket.

Verification

• Before starting engine, verify all electrical connectors are attached and all fluid levels are correct.
• Remove all tools from engine compartment and verify no loose hardware remains.
• Turn ignition to ON position (do not start) and check for fuel leaks at fuel rail connections.
• Prime oil system by cranking engine for 5-10 seconds without starting (disable ignition or fuel).
• Start engine and immediately check for oil pressure indication on gauge.
• Allow engine to idle and monitor for coolant leaks, oil leaks, exhaust leaks, and abnormal noises.
• As engine warms, coolant level will drop - add coolant to radiator as needed with engine idling until level stabilizes.
• Burp cooling system by squeezing upper radiator hose while engine is warm to release air pockets.
• Allow engine to reach full operating temperature and verify cooling fans cycle properly.
• Install radiator cap after cooling system is fully burped and coolant level is stable.
• Check and top off coolant overflow reservoir to proper level.
• Perform final inspection for any fluid leaks after 20 minutes of operation at operating temperature.
• Recheck oil level after engine has been off for 5 minutes - top off if necessary.
• Road test vehicle and verify normal engine performance, no overheating, and no warning lights.
• After first 500 miles, inspect cylinder head area for any seepage and recheck fluid levels.

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