FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it's easier than using pre cut 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.
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- Remove the strut tower support (1).
- Release fuel rail pressure then disconnect the fuel supply quick connect fitting at the fuel rail. Refer to «STANDARD PROCEDURE»(ref-288225-S42279264532008062000000) . Refer to «STANDARD PROCEDURE»(ref-288225-S01749820952008062000000) .
- Disconnect the battery negative and positive cables.
- Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine.
- Remove the through bolt retaining nut and bolt (3) from both the left and right side engine mounts. 1 - CRANKSHAFT POSITION SENSOR 2 - CYLINDER HEAD COVER 3 - CAMSHAFT POSITION SENSOR 4 - RIGHT SIDE CYLINDER BLOCK
- Disconnect crankshaft position sensor (1).
- Remove exhaust crossover pipe from exhaust manifolds.
- Remove structural cover. See «REMOVAL»(ref-288238-S26451028492008062000000) . 1 - EYELET TERMINAL 2 - NUT 3 - SCREW AND WASHER (2) 4 - STARTER MOTOR 5 - WIRE HARNESS CONNECTOR
- Remove starter (4). Refer to «REMOVAL»(ref-288245-S38009130742008062000000) . 1 - TRANSMISSION 2 - DRIVEPLATE 3 - TORQUE CONVERTER BOLTS
- Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-288235-S07920148752008062000000) .
- Remove torque converter bolts (3) (Automatic Transmission Only). 1 - ENGINE 2 - TRANSMISSION 3 - BOLTS 4 - WIRING HARNESS CLIPS
- Remove transmission to engine mounting bolts (3).
- Disconnect the engine block heater power cable from the block heater, if equipped.
- Lower vehicle.
- Remove throttle body resonator assembly and air inlet hose.
- Disconnect throttle and speed control cables. 1 - CRANKCASE BREATHERS
- Disconnect tube from both the left and right side crankcase breathers (1). Remove breathers.
- Discharge A/C system. Refer to «STANDARD PROCEDURE»(ref-288218-S28871183162008062000000) .
- Remove A/C compressor (2). Refer to «REMOVAL»(ref-288218-S07276443922008062000000) . 1 - LOWER BOLTS 2 - REAR BOLT 3 - GENERATOR
- Remove shroud, fan assembly and accessory drive belt. Refer to «REMOVAL»(ref-288235-S05444885892008062000000) and «REMOVAL»(ref-288235-S32167489122008062000000)
- Disconnect transmission oil cooler lines at the radiator.
- Disconnect radiator upper and lower hoses.
- Remove radiator, A/C condenser and transmission oil cooler. Refer to «REMOVAL»(ref-288235-S15830978672008062000000) and «REMOVAL»(ref-288218-S32893439912008062000000) .
- Remove generator (3). Refer to «REMOVAL»(ref-288243-S39870320522008062000000) . 1 - HEATER HOSES AND TUBES 2 - ROUTING/RETAINING CLIPS
- Disconnect the two heater hoses from the timing chain cover and heater core.
- 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
- 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
- Disconnect the vacuum lines at the throttle body and intake manifold.
- 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
- Install Special Tools 8400 Lifting Studs, into the cylinder heads.
- 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
- Disconnect body ground strap (3) at the right side cowl. 1 - NUT 2 - GROUND STRAP 3 - BRAKE BOOSTER
- 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.
- Position a suitable jack under the transmission.
- Remove engine from the vehicle.