Service Information - 3.7L Engine: Application Dodge Dakota III

FORM-IN-PLACE GASKET AND SEALER APPLICATION

Assembling parts using a form-in-place gasket requires care but it's easier than using precut gaskets.

Mopar(R) 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(R) 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(R) 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 (1).

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).
3. Drill motor with 3M Roloc(tm) Bristle Disc (white or yellow) (2).

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1. Release fuel rail pressure «(Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE)»(ref-247623-S20291972152007020100000) then disconnect the fuel supply quick connect fitting at the fuel rail «(Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE)»(ref-247623-S32073100012007020100000) .
2. Disconnect the battery negative cable.
3. Remove air cleaner assembly.
4. Remove fan shroud with viscous fan assembly.
5. Remove drive belt.
6. Remove A/C compressor (2) and secure away from engine. 1 - LOWER BOLTS 2 - REAR BOLT 3 - GENERATOR
7. Remove generator (3) and secure away from engine. NOTE: Do NOT remove the phenolic pulley from the P/S pump. It is not required for P/S pump removal.
8. Remove power steering pump with lines attached and secure away from engine.
9. Drain cooling system.
10. Disconnect the heater hoses from the engine.
11. Disconnect heater hoses from heater core and remove hose assembly.
12. Disconnect throttle and speed control cables.
13. Remove upper radiator hose from engine.
14. Remove lower radiator hose from engine.
15. Remove radiator/cooling module assembly.
16. Disconnect the engine to body ground straps at the left side of cowl. 1 - THROTTLE BODY 2 - TPS 3 - IAC MOTOR 4 - IAT SENSOR (THREADED TYPE) 5 - MOUNTING SCREWS
17. Disconnect the engine wiring harness at the following points: Intake air temperature (IAT) sensor (4) Fuel Injectors Throttle Position (TPS) Switch (2) Idle Air Control (IAC) Motor (3) Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold Absolute Pressure MAP) Sensor Camshaft Position (CMP) Sensor Coil Over Plugs Crankshaft Position Sensor
18. Remove coil over plugs.
19. Remove fuel rail and secure away from engine. NOTE: It is not necessary to release the quick connect fitting from the fuel supply line for engine removal.
20. Remove the PCV hose.
21. Remove the breather hoses.
22. Remove the vacuum hose for the power brake booster.
23. Disconnect knock sensors.
24. Remove engine oil dipstick tube.
25. Remove intake manifold.
26. Install engine lifting fixture, special tool # 8247, using original fasteners from the removed intake manifold, and fuel rail. Torque to factory specifications. NOTE: Recheck bolt torque for engine lift plate before removing engine. 1 - EYELET TERMINAL 2 - NUT 3 - SCREW AND WASHER (2) 4 - STARTER MOTOR 5 - WIRE HARNESS CONNECTOR
27. Disconnect oxygen sensor wiring.
28. Disconnect crankshaft position sensor.
29. Disconnect the engine block heater power cable, if equipped.
30. Disconnect the front propshaft at the front differential and secure out of way.
31. Remove the pinion bracket. NOTE: It is necessary to disconnect the front propshaft for access to the starter and left side exhaust flange.
32. Remove the starter (4). 1 - NUT 2 - A/C ACCUMULATOR 3 - GROUND STRAP 1 - NUT 2 - GROUND STRAP 3 - BRAKE BOOSTER
33. Remove the ground straps from the left (2) and right (3) side of the block. 1 - BOLT 2 - BOLT 3 - BOLT
34. Remove the structural cover.
35. Disconnect the right and left exhaust pipes at the manifolds and from the crossover, and remove from the vehicle. 1 - TRANSMISSION 2 - DRIVE PLATE 3 - TORQUE CONVERTER BOLTS
36. Remove torque convertor bolts (3), and mark location for reassembly. 1 - ENGINE 2 - TRANSMISSION 3 - BOLTS 4 - WIRING HARNESS CLIPS
37. Remove transmission bellhousing to engine bolts (3).
38. Remove left and right engine mount thru bolts (3).
39. Lower the vehicle.
40. Support the transmission with a suitable jack.
41. Connect a suitable engine hoist to the engine lift plate.
42. Remove engine from vehicle.

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1. Position the engine in the vehicle.
2. Install the transmission bellhousing to engine mounting bolts (3). Tighten the bolts to 41 N.m (30 ft. lbs.)
3. Install the engine mount thru bolts. 1 - TRANSMISSION 2 - DRIVE PLATE 3 - TORQUE CONVERTER BOLTS
4. Install the torque convertor bolts (3). 1 - EYELET TERMINAL 2 - NUT 3 - SCREW AND WASHER (2) 4 - STARTER MOTOR 5 - WIRE HARNESS CONNECTOR
5. Install the starter (4).
6. Connect the crankshaft position sensor.
7. Install the engine block heater power cable, if equipped. 1 - BOLT 2 - BOLT 3 - BOLT CAUTION: The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.
8. Install the structural cover.
9. Install the pinion bracket.
10. Install the left and right exhaust pipes.
11. Connect the left and right oxygen sensors.
12. Remove the engine lift plate.
13. Connect the knock sensors.
14. Connect the engine to body ground straps at the left side of the cowl.
15. Install the intake manifold using the sequence provided.
16. Install the engine oil dipstick tube.
17. Install the power brake booster vacuum hose.
18. Install the breather hoses.
19. Install the PCV hose.
20. Install the fuel rail.
21. Install the coil over plugs. 1 - THROTTLE BODY 2 - TPS 3 - IAC MOTOR 4 - IAT SENSOR (THREADED TYPE) 5 - MOUNTING SCREWS
22. Connect the engine wiring harness at the following points: Intake air temperature (IAT) sensor (4) Fuel Injectors Throttle Position (TPS) Switch (2) Idle Air Control (IAC) Motor (3) Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold Absolute Pressure MAP) Sensor Camshaft Position (CMP) Sensor Coil Over Plugs Crankshaft Position Sensor 1 - NUT 2 - A/C ACCUMULATOR 3 - GROUND STRAP
23. Connect the ground straps on the right (3) side of the engine. 1 - NUT 2 - GROUND STRAP 3 - BRAKE BOOSTER
24. Connect the ground straps on the left (2) side of the engine. 1 - LOWER BOLTS 2 - REAR BOLT 3 - GENERATOR
25. Reinstall the radiator/cooling module assembly.
26. Connect lower radiator hose.
27. Connect upper radiator hose.
28. Connect throttle and speed control cables.
29. Install the heater hose assembly.
30. Install coolant recovery bottle.
31. Install the power steering pump.
32. Install the generator (3).
33. Install the A/C compressor (2).
34. Install the drive belt.
35. Install the fan shroud with the viscous fan assembly.
36. Install the radiator core support bracket.
37. Recharge the A/C system. Refer to «REFRIGERANT SYSTEM CHARGE»(ref-247627-S17668097332007020100000) .
38. Install the air cleaner assembly.
39. Refill the engine cooling system.
40. Check and fill engine oil.
41. Connect the battery negative cable.
42. Start the engine and check for leaks.