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Service Information - 4.7L Engine: Application Dodge Dakota III

Mechanical 26 illustrations ~1565 words

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® 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.

Scheme 259

Scheme 259: REMOVAL - ENGINE
Scheme 259: REMOVAL - ENGINE
1 - CRANKSHAFT POSITION SENSOR
2 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK

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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 and positive cables.
  3. Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine.
  4. Remove the through bolt retaining nut and bolt (3) from both the left and right side engine mounts.
  5. Disconnect crankshaft position sensor (1). 1 - BOLT 2 - BOLT 3 - BOLT
  6. Remove exhaust crossover pipe from exhaust manifolds.
  7. Remove the pinion bracket.
  8. Remove structural cover «(Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COVER - REMOVAL)»(ref-247617-S09745140682007020100000) . 1 - EYELET TERMINAL 2 - NUT 3 - SCREW AND WASHER (2) 4 - STARTER MOTOR 5 - WIRE HARNESS CONNECTOR
  9. Remove starter (4) «(Refer to ELECTRICAL/STARTING/STARTER MOTOR - REMOVAL)»(ref-247621-S06053010492007020100000) . 1 - TRANSMISSION 2 - DRIVE PLATE 3 - TORQUE CONVERTER BOLTS
  10. Drain cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-247624-S05505992522007020100000) .
  11. Remove torque converter bolts (3) (Automatic Transmission Only). 1 - ENGINE 2 - TRANSMISSION 3 - BOLTS 4 - WIRING HARNESS CLIPS
  12. Remove transmission to engine mounting bolts (3).
  13. Disconnect the engine block heater power cable from the block heater, if equipped.
  14. Lower vehicle.
  15. Remove throttle body resonator assembly and air inlet hose.
  16. Disconnect throttle and speed control cables. 1 - CRANKCASE BREATHERS
  17. Disconnect tube from both the left and right side crankcase breathers (1). Remove breathers.
  18. Discharge A/C system. Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-247627-S23474598522007020100000) .
  19. Remove A/C compressor (2) «(Refer to HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - REMOVAL)»(ref-247627-S37636794062007020100000) . 1 - LOWER BOLTS 2 - REAR BOLT 3 - GENERATOR
  20. Remove shroud, fan assembly and accessory drive belt (Refer to «FAN-RADIATOR VISCOUS»(ref-247624-S33967241402007020100000) and «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(ref-247624-S17004004882007020100000) .
  21. Disconnect transmission oil cooler lines at the radiator.
  22. Disconnect radiator upper and lower hoses.
  23. Remove radiator «(Refer to COOLING/ENGINE/RADIATOR - REMOVAL)»(ref-247624-S16750977712007020100000) , A/C condenser «(Refer to HEATING & AIR CONDITIONING/PLUMBING/A/C CONDENSER - REMOVAL)»(ref-247627-S21975614442007020100000) and transmission oil cooler.
  24. Remove generator (3) «(Refer to ELECTRICAL/CHARGING/GENERATOR - REMOVAL)»(ref-247626-S19200388042007020100000) . 1 - HEATER HOSES AND TUBES 2 - ROUTING/RETAINING CLIPS
  25. Disconnect the two heater hoses from the timing chain cover and heater core.
  26. Unclip (2) and remove heater hoses (1) and tubes from the intake manifold. 1 - THROTTLE BODY 2 - TPS 3 - IAC MOTOR 4 - IAT SENSOR (THREADED TYPE) 5 - MOUNTING SCREWS
  27. Disconnect engine 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
  28. Disconnect the vacuum lines at the throttle body and intake manifold.
  29. Remove power steering pump and position out of the way. 1 - ATTACHING LOCATION 2 - ADJUSTABLE HOOK 3 - SPECIAL TOOL 8347 ENGINE LIFT FIXTURE 4 - ATTACHING LOCATIONS
  30. Install Special Tools 8400 Lifting Studs, into the cylinder heads.
  31. Install Engine Lifting Fixture Special Tool 8347 (3) following these steps. Holding the lifting fixture at a slight angle, slide the large bore in the front plate over the hex portion of the lifting stud. Position the two remaining fixture arms onto the two Special Tools 8400 Lifting Studs, in the cylinder heads. Pull forward and upward on the lifting fixture so that the lifting stud rest in the slotted area below the large bore. Secure the lifting fixture to the three studs using three 7/16 - 14 N/C lock nuts. Make sure the lifting loop in the lifting fixture is in the last hole (closest to the throttle body) to minimize the angle of engine during removal. 1 - NUT 2 - A/C ACCUMULATOR 3 - GROUND STRAP
  32. Disconnect body ground strap (3) at the right side cowl. 1 - NUT 2 - GROUND STRAP 3 - BRAKE BOOSTER
  33. Disconnect body ground strap (2) at the left side cowl. NOTE: It will be necessary to support the transmission in order to remove the engine.
  34. Position a suitable jack under the transmission.
  35. Remove engine from the vehicle.

Scheme 272

Scheme 272: INSTALLATION - ENGINE
Scheme 272: INSTALLATION - ENGINE
1 - ATTACHING LOCATION
2 - ADJUSTABLE HOOK
3 - SPECIAL TOOL 8347 ENGINE LIFT FIXTURE
4 - ATTACHING LOCATIONS

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  1. Position engine in the vehicle.
  2. Remove jack from under the transmission.
  3. Remove Engine Lifting Fixture Special Tool 8347 (3).
  4. Remove Special Tools 8400 Lifting Studs.
  5. Position both the left and right side engine mount brackets and install the through bolts (3) and nuts. Tighten to 95 N.m (70 ft. lbs.) 1 - ENGINE 2 - TRANSMISSION 3 - BOLTS 4 - WIRING HARNESS CLIPS
  6. Install transmission to engine mounting bolts (3). Tighten the bolts to 41 N.m (30 ft. lbs.). 1 - TRANSMISSION 2 - DRIVE PLATE 3 - TORQUE CONVERTER BOLTS
  7. Install torque converter bolts (3). 1 - NUT 2 - A/C ACCUMULATOR 3 - GROUND STRAP 1 - NUT 2 - GROUND STRAP 3 - BRAKE BOOSTER
  8. Connect both left (2) and right (3) side body ground straps.
  9. Position generator wiring behind the oil dipstick tube, then install the oil dipstick tube upper mounting bolt.
  10. Install power steering pump.
  11. Connect fuel supply line quick connect fitting «(Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE)»(ref-247623-S32073100012007020100000) .
  12. Connect the vacuum lines at the throttle body and intake manifold. 1 - THROTTLE BODY 2 - TPS 3 - IAC MOTOR 4 - IAT SENSOR (THREADED TYPE) 5 - MOUNTING SCREWS
  13. Connect engine harness at the following points: Intake Air Temperature (IAT) Sensor (4) Idle Air Control (IAC) Motor (3) Fuel Injectors Throttle Position (TPS) Switch (2) Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold Absolute Pressure (MAP) Sensor Camshaft Position (CMP) Sensor Coil Over Plugs 1 - HEATER HOSES AND TUBES 2 - ROUTING/RETAINING CLIPS
  14. Position and install heater hoses (1) and tubes onto intake manifold.
  15. Install the heater hoses onto the heater core and the engine front cover, and install clips (2). 1 - LOWER BOLTS 2 - REAR BOLT 3 - GENERATOR
  16. Install generator (3) «(Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION)»(ref-247626-S41383718202007020100000) .
  17. Install A/C condenser «(Refer to HEATING & AIR CONDITIONING/PLUMBING/A/C CONDENSER - INSTALLATION)»(ref-247627-S41009426062007020100000) , radiator «(Refer to COOLING/ENGINE/RADIATOR - INSTALLATION)»(ref-247624-S01271631282007020100000) and transmission oil cooler.
  18. Connect radiator upper and lower hoses.
  19. Connect the transmission oil cooler lines to the radiator.
  20. Install accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-247624-S16163766032007020100000) , fan assembly (Refer to «FAN-RADIATOR VISCOUS»(ref-247624-S33967241402007020100000) ) and shroud.
  21. Install A/C compressor (2) «(Refer to HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION)»(ref-247627-S15861015232007020100000) . 1 - CRANKCASE BREATHERS
  22. Install both breathers (1). Connect tube to both crankcase breathers.
  23. Connect throttle and speed control cables.
  24. Install throttle body resonator assembly and air inlet hose. Tighten clamps 4 N.m (35 in. lbs.).
  25. Raise vehicle. 1 - CRANKSHAFT POSITION SENSOR 2 - CYLINDER HEAD COVER 3 - CAMSHAFT POSITION SENSOR 4 - RIGHT SIDE CYLINDER BLOCK
  26. Connect crankshaft position sensor (1). 1 - EYELET TERMINAL 2 - NUT 3 - SCREW AND WASHER (2) 4 - STARTER MOTOR 5 - WIRE HARNESS CONNECTOR
  27. Install starter (4) «(Refer to ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION)»(ref-247621-S42070693062007020100000) . 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.
  28. Install structural cover «(Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COVER - INSTALLATION)»(ref-247617-S25901074792007020100000) .
  29. Install the pinion bracket.
  30. Install exhaust crossover pipe.
  31. Install engine block heater power cable, If equipped.
  32. Check and fill engine oil.
  33. Recharge the A/C system. Refer to «REFRIGERANT SYSTEM CHARGE»(ref-247627-S17668097332007020100000) .
  34. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-247624-S05505992522007020100000) .
  35. Connect the battery positive and negative cables.
  36. Start the engine and check for leaks.

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