2.7L DOHC Engine - Service Information: Application Dodge Journey I

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.

Scheme 677

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.

Scheme 678

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Scheme 702

1. Remove the engine cover.
2. Release fuel pressure. Refer to «Fuel System/Fuel Delivery - Standard Procedure»(ref-353596-S39204571612010011200000) .
3. Disconnect negative battery cable.
4. Drain cooling system. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
5. Evacuate the A/C system using a suitable refrigerant recovery machine. Refer to «Heating and Air Conditioning/Plumbing - Standard Procedure»(ref-353571-S22405082752010011200000) .
6. Remove throttle body air inlet hose and air cleaner housing assembly. See «Engine/Air Intake System/BODY, Air Cleaner - Removal»(ref-353618-S37699768462010011200000) .
7. Raise vehicle on hoist.
8. Remove both front wheels. 1 - Belly Pan Fasteners 2 - Belly Pan
9. Remove fasteners (1), and remove the belly pan (2).
10. Remove the left lower splash shield (2).
11. Remove the right lower splash shield (2).
12. Remove the lower fascia closeout panel (2).
13. Lower vehicle.
14. Disconnect upper (2) and lower (1) radiator hoses at the thermostat housing and at the water pump fitting.
15. Disconnect transmission control module harness connector (1).
16. Disconnect transmission solenoid harness connectors (3) and (4).
17. Disconnect transmission input shaft speed sensor (2) and the output shaft speed sensor (5).
18. Disconnect transmission shift cable.
19. Disconnect the transaxle oil cooler lines at the transaxle.
20. Disconnect A/C discharge line (1) at compressor (2).
21. Disconnect A/C suction line (1) at compressor (2).
22. Remove the A/C compressor (3). Refer to «Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Removal»(ref-353571-S03338883732010011200000) .
23. Remove cooling fan assembly. Refer to «Cooling/Engine/FAN, Cooling - Removal»(ref-353584-S40318301502010011200000) .
24. Disconnect engine electrical harnesses connectors (1), (2) and (3).
25. Raise vehicle.
26. If equipped with AWD, remove the propeller shaft to PTU fasteners (2). Refer to «Differential and Driveline/Propeller Shaft - Removal»(ref-353569-S30582861682010011200000) .
27. Remove both axle shafts (2). Refer to «Differential and Driveline/Half Shaft - Removal»(ref-353569-S23433654932010011200000) .
28. Remove front engine mount through bolt (2). 1 - GENERATOR 2 - IDLER/TENSIONER
29. Remove accessory drive belts (2) and (5). Refer to «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353584-S03638748182010011200000) .
30. Remove power steering pump and bracket as an assembly. Do not disconnect power steering lines from pump. Reposition pump and support with suitable retaining strap.
31. Disconnect heater return hose (1) from pipe connection at right front frame rail area.
32. Remove structural collar (3). See «Engine/Engine Block/COVER, Structural Dust - Removal»(ref-353618-S23291173112010011200000) .
33. Remove the exhaust cross-under pipe (1). See «Engine/Manifolds/MANIFOLD, Exhaust - Removal»(ref-353618-S15381970382010011200000) .
34. Remove rear engine mount and transaxle bracket (2).
35. Drain engine oil.
36. Remove transaxle torque converter housing cover.
37. Mark flex plate to torque converter position. Remove torque converter bolts.
38. Lower vehicle.
39. Disconnect positive cable from battery and TIPM.
40. Disconnect ground cable from left side transaxle mount bracket.
41. Disconnect ETC harness connector (1) from throttle body.
42. Disconnect coolant pressure bottle coolant hose (1) from engine coolant outlet connector.
43. Disconnect heater hose (1) from engine coolant outlet below the ETC.
44. If equipped, disconnect the oil cooler lines (1) from the engine oil cooler.
45. Disconnect ground strap at right shock tower.
46. Disconnect fuel line (1) from fuel rail inlet (2).
47. Disconnect vapor purge vacuum hose (1).
48. Disconnect brake booster vacuum hose (1).
49. Disconnect all ground straps attaching to engine.
50. Position vehicle height to allow engine dolly 6135 and cradle 6710A with posts 6848 to be installed under vehicle.
51. Loosen cradle engine mounts to allow movement for positioning onto engine locating holes on the engine block, compressor mount bracket and oil pan rail. Lower vehicle and position cradle until the engine is resting on posts. Tighten post mounts to cradle frame to prevent movement when removing or installing engine/transaxle assembly. Secure engine/transaxle assembly to dolly/cradle with safety straps.
52. Lower vehicle so weight of the engine and transmission ONLY is on the cradle.
53. Remove right and left side engine mount bolts.
54. Slowly raise vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for removal clearance. 1 - SAFETY STRAPS 2 - SPECIAL TOOL 6135 3 - SPECIAL TOOL 6710

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Scheme 705

1. Position engine/transaxle assembly under vehicle and slowly lower vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for installation clearance.
2. Continue lowering vehicle until right side engine mount and left side transaxle mount align to their mounting locations. Install mounting bolts and torque to 61 N.m (45 ft. lbs.).
3. Remove safety straps from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly and cradle.
4. Reattach all ground straps to engine.
5. Connect brake booster vacuum hose (1).
6. Connect vapor purge vacuum hose (1).
7. Connect fuel line (1).
8. Connect ground strap to right shock tower.
9. Connect the heater hose (1) to the engine coolant outlet below the ETC.
10. If equipped, reconnect the oil cooler lines (1) from the engine oil cooler.
11. Connect coolant pressure bottle coolant hose (1) to coolant outlet connector.
12. Connect ETC harness connector (2).
13. Connect ground cable to right engine mount bracket.
14. Connect positive cable to battery and TIPM.
15. Raise vehicle.
16. Automatic Transmission Equipped Vehicles: Install torque converter bolts. Install torque converter housing cover.
17. Manual Transmission Equipped Vehicles: Install modular clutch assembly-to-drive plate bolts. Install clutch/drive plate inspection cover. Connect clutch hydraulic circuit quick connect fitting.
18. Install rear engine mount (2) and transaxle bracket.
19. Install exhaust cross-under pipe (1). See «Engine/Manifolds/MANIFOLD, Exhaust - Removal»(ref-353618-S15381970382010011200000) .
20. Install structural collar (3). See «Engine/Engine Block/COVER, Structural Dust - Installation»(ref-353618-S35987582342010011200000) .
21. Reconnect the heater return hose (1) from the pipe connection at the right front frame rail area.
22. Install A/C compressor (3) to bracket.
23. Connect A/C compressor clutch electrical connector.
24. Install power steering pump and bracket assembly. Refer to «Steering/Pump - Installation»(ref-353572-S40988039922010011200000) . 1 - GENERATOR 2 - IDLER/TENSIONER
25. Install accessory drive belts (2) and (5). Refer to «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353584-S15414070972010011200000) .
26. Install the fore-aft crossmember. Refer to «Frame and Bumpers/Frame/CROSSMEMBER - Installation»(ref-353568-S00602877582010011200000) .
27. Install front engine mount through bolt (2).
28. Connect the propeller shaft (3) to the PTU. Refer to «Differential and Driveline/Propeller Shaft - Installation»(ref-353569-S22009109082010011200000) .
29. Install both axle shafts (2). Refer to «Differential and Driveline/Half Shaft - Installation»(ref-353569-S33188263152010011200000) .
30. Lower vehicle.
31. Install the cooling fan assembly. Refer to «Cooling/Engine/FAN, Cooling - Installation»(ref-353584-S41323013652010011200000) .
32. Connect engine electrical harness connectors (1), (2), and (3) to PCM and bulkhead connectors.
33. Automatic Transmission Equipped Vehicles: Connect transmission shift cable. Connect transmission electrical harness connectors (1), (2), (3), (4) and (5). Connect transmission oil cooler lines.
34. Manual Transmission Equipped Vehicles: Connect transmission shift cables. Refer to «Transmission and Transfer Case/Manual/CABLE, Gearshift Control - Installation»(ref-353583-S20270124312010011200000) . Connect back up lamp switch connector.
35. Connect upper (2) and lower (1) radiator hoses.
36. Raise vehicle.
37. Ensure oil pan drain plug is installed. Install new oil filter.
38. Install left lower splash shield (2).
39. Install the right splash shield (2).
40. Install both front wheels (1).
41. Lower vehicle.
42. Install throttle body air inlet hose and air cleaner housing assembly. See «Engine/Air Intake System/BODY, Air Cleaner - Installation»(ref-353618-S14117192912010011200000) .
43. Fill engine crankcase with proper oil to correct level.
44. Evacuate and recharge Air Conditioning system. Refer to «Heating and Air Conditioning/Plumbing - Standard Procedure»(ref-353571-S22405082752010011200000) .
45. Fill cooling system. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
46. Connect negative battery cable.
47. Start engine and run until operating temperature is reached. Inspect for leaks, and verify normal operation. NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to «DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure»(ref-353603-S03528494482010011200000) .