2.7L DOHC Engine - Service Information: Application Dodge Charger V

SEALER APPLICATION

Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) 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 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) 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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To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

Never use the following to clean gasket surfaces

1. Metal scraper
2. Abrasive pad or paper to clean cylinder block and head
3. High speed power tool with an abrasive pad or a wire brush

Note. Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Only use the following for cleaning gasket surfaces

1. Solvent or a commercially available gasket remover
2. Plastic or wood scraper
3. Drill motor with 3M Roloc™ Bristle Disc (white or yellow)

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Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug.

Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopar® Stud and Bearing Mount. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer.

It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately.

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1. Remove hood.
2. Release fuel pressure «(Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE)»(ref-255958-S27716034072007060500000) .
3. Disconnect negative battery cable located in the trunk.
4. Disconnect intake air temperature sensor electrical connector.
5. Remove air cleaner housing assembly (3) «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(ref-255938-S11929698952007060500000) .
6. Remove accessory drive belt (5) «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(ref-255951-S25277980112007060500000) .
7. Disconnect lines from power steering pump (3).
8. Remove power steering pump attaching bolts and set pump aside (3).
9. Recover A/C system using a suitable refrigerant recovery machine «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE)»(ref-255976-S38397795242007060500000) .
10. Disconnect A/C compressor (4) electrical connectors.
11. Remove A/C compressor (4) «(Refer to HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - REMOVAL)»(ref-255976-S14245294602007060500000) .
12. Raise vehicle.
13. Remove lower splash shield bolts (1) and remove splash shield (2).
14. Drain cooling system (Refer to «STANDARD PROCEDURE»(ref-255951-S06865140152007060500000) ).
15. Drain the engine oil (5) and remove the oil filter (3).
16. Disconnect down stream oxygen sensor connectors.
17. Disconnect exhaust pipes at the manifolds.
18. Disconnect starter (2) electrical connectors.
19. Remove starter (2) bolts and set starter aside.
20. Disconnect coolant pipe (1) near starter from hose.
21. Disconnect crankshaft position sensor electrical connector and remove sensor «(Refer to FUEL SYSTEM/FUEL INJECTION/CRANKSHAFT POSITION SENSOR - REMOVAL)»(ref-255958-S07872065432007060500000) .
22. Disconnect ground strap.
23. Disconnect oil pressure sensor (1) electrical connector.
24. Remove 4 engine mount nuts (1).
25. Remove engine mount studs (1) from mount.
26. Remove steering gear mounting bolts (1) and lower steering gear (2) for clearance.
27. Using a block of wood and a suitable lifting device under the oil pan, raise the engine.
28. Remove structural collar bolts (2 & 4).
29. Remove structural collar (3).
30. Remove lower bell housing bolts.
31. Lower engine and remove jack stand.
32. Mark flex plate to torque converter location.
33. Remove torque converter bolts.
34. Lower vehicle.
35. Remove wiper arms «(Refer to ELECTRICAL/WIPERS/WASHERS/WIPER ARMS - REMOVAL)»(ref-255937-S12892838602007060500000) .
36. Remove wiper cowl (1) «(Refer to ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - REMOVAL)»(ref-255937-S13480458892007060500000) .
37. Remove strut tower support (2).
38. Reposition purge solenoid (5).
39. Remove the intake manifold (2) «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(ref-255938-S39869547212007060500000) .
40. Disconnect all vacuum lines and electrical connectors.
41. Disconnect all ground straps attaching to the engine.
42. Disconnect fuel line at fuel rail (1).
43. Disconnect coil, injector (2), capacitor, and knock sensor connectors.
44. Remove EGR valve and tube assembly «(Refer to EMISSIONS CONTROL/EXHAUST GAS RECIRCULATION/VALVE - REMOVAL)»(ref-255936-S20884705102007060500000) .
45. Remove upper bellhousing bolts and reposition electrical harness.
46. Attach special tool #8342A (1). Attach special tool #8342A to the front of the left cylinder head (2). Attach special tool #8342A to the rear of the right cylinder head (3).
47. Support transmission with a block of wood and floor jack.
48. Hoist engine from engine compartment.