I've had overheating problems for a long time now. Changed all the easy stuff (thermostat, rad cap, hoses, radiator, fan clutch, belt, belt tensioner) but it still overheats especially under heavy load. Someone said do a leak down test, so I bought a tester and finally did that. I expected a bad head gasket but saw no bubbles in the radiator. But found cyls 5 and 7 low. Likely burned valves since I heard hissing in the exhaust pipe while applying pressure to the cylinders. So I need to remove the cylinder heads. This does not look easy since I noticed that the exhaust manifolds need to be separated from the heads in order to get at all the head bolts. Since its 13 years old, there is plenty of rust on the exhaust manifold bolts. In fact one is already broken off. There is bound to be problems loosening the rest plus not much working space. Has anyone out there actually removed the heads without removing the engine from the van? Is there any advice on this subject?
Also, I cant seem to find a good repair manual specifically for this van. Most I've seen are just generic without any procedural details.
Any help is appreciated.

 

For a manual nothing beats a factory service manual. You can sometimes find them used on eBay dirt cheap.

As to the manifolds, you might be stuck have to buy a new pairs and just cutting the old ones off with a sawzall.

 

Chrysler techauthority probably still has the original tech manual available.
They had one for our 2001 B1500.
On these older vehicles they are very reasonable; less than $30. shipped to Dallas for the 2001. That's a 1200 pg manual!!
The manual is cheaper than a generic covers nothing manual at autozone.
Most other companies charge much more for a tech manual if they have it available.
I do not no why techauthority is not more promo gated on a Dodge website!!!
We need to really get the word out thatMa Chrysler has the best tech support of any of the major automotive companies.
support@techauthority.com will actually get you a reply when you email them..