Dodge Nitro. Manual — part 69

Fig. 4: Removing Core Hole Plug
Courtesy of CHRYSLER LLC

Using a blunt tool such as a drift (3) and a hammer, strike the bottom edge of the cup plug (5). With the cup
plug rotated, grasp firmly with pliers (2) or other suitable tool and remove plug (5). See Fig. 4

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.

1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG

CAUTION: Do not drive cup plug into the casting as restricted cooling can result and

cause serious engine problems.

2007 Dodge Nitro R/T

2007 ENGINE 4.0L - Service Information - Nitro

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

ENGINE GASKET SURFACE PREPARATION

Fig. 5: Proper Tool Usage for Surface Preparation
Courtesy of CHRYSLER LLC

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 - ABRASIVE PAD
2 - 3M ROLOC™ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER

2007 Dodge Nitro R/T

2007 ENGINE 4.0L - Service Information - Nitro

Metal scraper

Abrasive pad or paper to clean cylinder block and head

High speed power tool with an abrasive pad or a wire brush. See Fig. 5

Only use the following for cleaning gasket surfaces:

Solvent or a commercially available gasket remover

Plastic or wood scraper. See Fig. 5

Drill motor with 3M Roloc™ Bristle Disc (white or yellow). See Fig. 5

HYDROSTATIC LOCKED ENGINE

When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following
steps should be used.

1. Inspect air cleaner, induction system and intake manifold to insure system is dry and clear of foreign

material.

2. Remove negative battery cable.

3. Place a shop towel around the spark plugs when removing them from the engine. This will catch any fluid

that may possibly be in the cylinder under pressure.

4. With all spark plugs removed, rotate engine crankshaft using a breaker bar and socket.

5. Identify the fluid in the cylinder(s) (i.e, coolant, fuel, oil or other).

6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e, connecting rods,

pistons, valves, etc.)

7. Repair engine or components as necessary to prevent this problem from re-occurring.

8. Install new spark plugs.

9. Drain engine oil and remove oil filter.

NOTE:

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

CAUTION: Excessive pressure or high RPM (beyond the recommended speed), can

damage the sealing surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80 grit) bristle disc may
be used on cast iron surfaces with care.

CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur.

CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotate

engine to lubricate the cylinder walls to prevent damage on restart.

2007 Dodge Nitro R/T

2007 ENGINE 4.0L - Service Information - Nitro

10. Install a new oil filter.

11. Fill engine with specified amount of approved oil.

12. Connect negative battery cable.

13. Start engine and check for any leaks.

REMOVAL

ENGINE ASSEMBLY-REMOVAL

Fig. 6: Disconnecting Negative Battery Cable
Courtesy of CHRYSLER LLC

1. Perform the fuel pressure release procedure. Refer to STANDARD PROCEDURE .

2. Disconnect negative battery cable (2).

3. Evacuate the air conditioning system. Refer to STANDARD PROCEDURE .

4. Remove the hood.

Fig. 7: Disconnecting Lower Radiator Hose

2007 Dodge Nitro R/T

2007 ENGINE 4.0L - Service Information - Nitro