Sealer Application Chrysler Crossfire I final

Mopar® Gasket Maker material should be applied sparingly, 0.040 in. (1 mm) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 0.120 in. (3 mm) in diameter. All mounting holes must be circled. For corner sealing, a 1/8 or 1/4 in. (3.17 or 6.35 mm) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets.

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1. Disconnect the negative battery cable.
2. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-306586-S31939057842008121700000) .
3. Remove the air cleaner housing assembly. See «REMOVAL»(ref-306563-S23334034382008121700000) .
4. Relieve the fuel pressure at the service valve (1) on the fuel rail. Refer to «STANDARD PROCEDURE»(ref-306570-S09730965222008121700000) .
5. Remove the radiator and radiator fan assembly. Refer to «REMOVAL»(ref-306586-S11111296082008121700000) .
6. Remove the accessory drive belt. Refer to «REMOVAL»(ref-306586-S22742124262008121700000) .
7. Disconnect the vacuum hoses at the brake booster, intake manifold, and the purge valve.
8. Remove the oil from the power steering pump reservoir.
9. Disconnect the ground lead at the power steering pump.
10. Disconnect the pressure (2) and return (1) lines from the power steering pump.
11. Disconnect the oxygen sensor harness connectors (1), MAF sensor harness connector (2), heater hose (3) at rear of engine, and the fuel supply line (4) at the fuel rail.
12. Disconnect the ignition coil(s), fuel injector(s), camshaft position sensor, crankshaft position sensor, throttle position sensor, map sensor, engine coolant temperature sensor, EGR solenoid, air pump, air pump switchover solenoid, A/C compressor, and generator harness connectors. Reposition the engine harness out of the way.
13. Remove the lower radiator hose (1) and the coolant bypass hose (2) from the water pump.
14. Remove the upper radiator hose (1) from the thermostat housing.
15. Raise and support the vehicle.
16. Remove the lower splash shield retaining screws (1) and the splash shield (2).
17. Remove the front exhaust pipes. Refer to «REMOVAL»(ref-306569-S17295290192008121700000) .
18. Disconnect the ground cable (1) at the transmission.
19. Remove the propeller shaft. Refer to «REMOVAL»(ref-306561-S40217325232008121700000) .
20. Remove the starter motor. Refer to «REMOVAL»(ref-306562-S03201732402008121700000) .
21. Remove the transmission. For Automatic, refer to «REMOVAL»(ref-306559-S35664687552008121700000) , or for Manual, refer to «REMOVAL»(ref-306584-S35500008242008121700000) .
22. Remove the A/C compressor mounting bolts and position the A/C compressor out of the way with lines attached. Refer to «REMOVAL»(ref-306578-S03114181512008121700000) .
23. Remove the front engine mount bolts (1).
24. Lower the vehicle.
25. Attach the engine lifting device to the engine lifting eyes.
26. Remove the engine assembly from the vehicle.
27. Mount the engine on an engine stand.

1. Attach the lifting device to the engine lifting eyes.
2. Remove the engine from the engine stand.
3. Lower the engine into the engine compartment and install the lower engine mount bolts (1). Tighten bolts to 55 N.m (41 ft. lbs.).
4. Install the transmission. For Automatic, refer to «INSTALLATION»(ref-306559-S24957390122008121700000) , or for Manual, refer to «INSTALLATION»(ref-306584-S24680645932008121700000) .
5. Install the A/C compressor. Refer to «INSTALLATION»(ref-306578-S30996779772008121700000) .
6. Bolt on the ground cable at the transmission (1). Tighten to 40 N.m (30 ft. lbs.).
7. Install the starter. Refer to «INSTALLATION»(ref-306562-S22126829442008121700000) .
8. Install the propeller shaft. Refer to «INSTALLATION»(ref-306561-S14472986452008121700000) .
9. Install the front exhaust pipes. Refer to «INSTALLATION»(ref-306569-S16573602502008121700000) .
10. Install the lower splash shield (2). Tighten the screws (1) to 5 N.m (44 in. lbs.).
11. Lower the vehicle.
12. Connect the lower radiator hose (1) and the coolant bypass hose (2) at the water pump.
13. Connect the heater hoses at the engine block and the intake manifold.
14. Connect the upper radiator hose (1) at the thermostat housing.
15. Connect the engine wire harness.
16. Connect the fuel supply line (4) at the fuel rail. Tighten the fitting to 38 N.m (28 ft. lbs.).
17. Connect the oxygen sensor harness connector (1), MAF sensor harness connector (2), and the heater hose (3) at rear of engine.
18. Connect the ignition coil(s), fuel injector(s), camshaft position sensor, crankshaft position sensor, throttle position sensor, map sensor, engine coolant temperature sensor, EGR solenoid, air pump, air pump switchover solenoid, A/C compressor, and generator harness connectors.
19. Connect the power steering pressure (2) and return line (1) to the power steering pump. Tighten the high pressure fitting to 45 N.m (33 ft. lbs.).
20. Connect the ground lead at the power steering pump. Tighten the bolt to 25 N.m (18 ft. lbs.).
21. Refill the power steering pump fluid reservoir.
22. Connect the vacuum hoses at the brake booster, intake manifold, and the purge valve.
23. Install the accessory drive belt. Refer to «INSTALLATION»(ref-306586-S10147609092008121700000) .
24. Install and connect the radiator with the radiator fan. Refer to «INSTALLATION»(ref-306586-S11683754282008121700000) .
25. Install the air cleaner assembly. See «INSTALLATION»(ref-306563-S35429154772008121700000) .
26. Connect the negative battery cable.
27. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-306586-S31939057842008121700000) .
28. Fill the engine with engine oil. See «STANDARD PROCEDURE»(ref-306563-S17946985482008121700000) .
29. Start the engine and check for leaks.
30. Recheck all fluid levels.