charging DODGE DURANGO 1997 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine SERVICE DIAGNOSISÐPERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary.
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to the terminals.
3. Faulty starter. 3. Refer to Group 8A, Battery/
Starter/ Charging System
Diagnostics.
4. Moisture on ignition wires and
distributor cap.4. Wipe wires and cap clean and
dry.
5. Faulty ignition cables. 5. Replace as necessary.
6. Faulty coil or control unit. 6. Refer to Group 8D, Ignition
System.
7. Incorrect spark plug gap. 7. Refer to Group 8D, Ignition
System.
8. Incorrect ignition timing. 8. Refer to Group 8D, Ignition
System.
9. Dirt or water in fuel system. 9. Clean system and replace fuel
filter.
10. Faulty fuel pump, relay or
wiring.10. Refer to Group 14, Fuel System.
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low. 1. Refer to Group 14, Fuel System.
2. Idle mixture to lean or to rich. 2. Refer to Group 14, Fuel System.
3. Vacuum leak. 3. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.
4. Worn or burned distributor rotor. 4. Replace distributor rotor.
5. Incorrect ignition wiring. 5. Install correct wiring.
6. Faulty coil. 6. Refer to Group 8D, Ignition
System.
7. EGR valve leaking. 7. Refer to Group 25, Emissions
Control System.
8. Incorrect cam timing. 8. Refer to Valve Timing in this
section.
9 - 8 4.7L ENGINEDN
DIAGNOSIS AND TESTING (Continued)

Downloaded from www.Manualslib.com manuals search engine (9) Disconnect the accelerator linkage.
(10) Remove throttle body.
(11) Perform the Fuel System Pressure release
procedure (refer to Group 14, fuel System).
(12) Disconnect the fuel supply line.
(13) Disconnect the starter wires.
(14) Disconnect the oil pressure sending unit wire.
(15) Discharge the air conditioning system, if
equipped (refer to Group 24, Heating and Air Condi-
tioning for service procedures).
(16) Disconnect the air conditioning hoses.
(17) Disconnect the power steering hoses, if
equipped.
(18) Remove starter motor (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(19) Remove the generator (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(20) Raise and support the vehicle on a hoist.
(21) Disconnect exhaust pipe at manifold.
(22) Refer to Group 21, Transmissions for trans-
mission removal.
CAUTION: DO NOT lift the engine by the intake
manifold.
(23) Install an engine lifting fixture.
(24) The engine and front driving axle (engine/ax-
le/transmission) are connected through insulators
and support brackets. Separate the engine as follows:
²LEFT SIDEÐRemove 2 bolts attaching
(engine/pinion nose/transmission) bracket to trans-
mission bell housing. Remove 2 bracket to pinion
nose adaptor bolts. Separate engine from insulator by
removing upper nut washer assembly and bolt from
engine support bracket.
²RIGHT SIDEÐRemove 2 bracket to axle (dis-
connect housing) bolts and a bracket to bell housing
bolt. Separate engine from insulator by removing
upper nut washer assembly and bolt from engine
support bracket.
(25) Lower the vehicle.
(26) Install engine assembly on engine repair
stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Install the engine front mounts.
(5) Refer to Group, 21 Transmissions for transmis-
sion installation
(6) Install the inspection plate.
(7) Remove transmission support.
(8) Install exhaust pipe to manifold.
(9) Lower the vehicle.
(10) Remove engine lifting fixture.(11) Install the generator (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(12) Install starter motor (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(13) Connect power steering hoses, if equipped.
(14) Connect air conditioning hoses.
(15) Evacuate and charge the air conditioning sys-
tem, if equipped (refer to Group 24, Heater and Air
Conditioning for service procedures).
(16) Using a new gasket, install throttle body.
Tighten the throttle body bolts to 23 N´m (200 in.
lbs.) torque.
(17) Connect the accelerator linkage.
(18) Connect the starter wires.
(19) Connect the oil pressure sending unit wire.
(20) Install the distributor cap and wiring.
(21) Connect the vacuum supply lines to the
intake manifold.
(22) Connect the fuel supply lines.
(23) Install the radiator (refer to Group 7, Cooling
System). Connect the radiator hoses and heater
hoses.
(24) Install fan shroud in position.
(25) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure).
(26) Install the air cleaner.
(27) Install the battery.
(28) Warm engine and adjust.
(29) Install hood and line up with the scribe
marks.
(30) Road test vehicle.
INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain the cooling system. Refer to COOLING
SYSTEM.
(3) Remove the A/C compressor. Refer to HEAT-
ING and AIR CONDITIONING.
(4) Remove the generator. Refer to CHARGING
SYSTEM.
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner assembly and air inlet
hose.
(7) Perform the fuel pressure release procedure.
Refer to FUEL SYSTEM.
(8) Disconnect the fuel supply line from the fuel
rail. Refer to FUEL SYSTEM.
(9) Disconnect the accelerator linkage and, if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the coolant temperature sending
unit wire.
DN5.2L ENGINE 9 - 103
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine SERVICE DIAGNOSISÐGASOLINE ENGINES
PERFORMANCE DIAGNOSIS CHARTÐGASOLINE ENGINES
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL
NOT CRANK1. Weak or dead battery 1. Charge/Replace Battery. Refer to Group 8A,
Battery, for correct procedures. Check charging
system. Refer to Group 8C, Charging Systems, for
correct procedures.
2. Corroded or loose battery
connections2. Clean/tighten suspect battery/starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. Refer to Group 8B,
Starting Systems, for correct diagnostics/procedures
4. Seized accessory drive
component4. Remove accessory drive belt and attempt to start
engine. If engine starts, repair/replace seized
component.
5. Engine internal mechanical
failure or hydro-static lock5. Refer to Group 9, Engine, for correct diagnostics/
procedures
ENGINE CRANKS
BUT WILL NOT
START1. No spark 1. Check for spark. Refer to Group 8D, Ignition
System, for correct procedures.
2. No fuel 2. Perform fuel pressure test, and if necessary,
inspect fuel injector(s) and driver circuits. Refer to
Group 14, Fuel System, for correct procedures.
3. Low or no engine compression 3. Perform cylinder compression pressure test. Refer
to Group 9, Engine, for correct procedures.
ENGINE LOSS OF
POWER1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor (Refer to Group 8D,
Ignition System
3. Worn or incorrect gapped spark
plugs3. Clean plugs and set gap. (Refer to Group 8D,
Ignition System)
4. Dirt or water in fuel system 4. Clean system and replace fuel filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression
9. Burned, warped, or pitted valves 9. Install/Reface valves as necessary
10. Plugged or restricted exhaust
system10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted cables
12. Faulty ignition coil 12. Test and replace, as necessary (Refer to Group
8D, Ignition System)
ENGINE STALLS
OR ROUGH IDLE1. Carbon build-up on throttle plate 1. Remove throttle body and de-carbon. (Refer to
Group 14 for correct procedures)
2. Engine idle speed too low 2. Check Idle Air Control circuit. (Refer to Group 14,
Fuel System)
9 - 142 5.9L ENGINEDN
DIAGNOSIS AND TESTING (Continued)

Downloaded from www.Manualslib.com manuals search engine INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain the cooling system. Refer to COOLING
SYSTEM.
(3) Remove the A/C compressor. Refer to HEAT-
ING and AIR CONDITIONING.
(4) Remove the generator. Refer to CHARGING
SYSTEM.
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner assembly and air inlet
hose.
(7) Perform the fuel pressure release procedure.
Refer to FUEL SYSTEM.
(8) Disconnect the fuel supply line from the fuel
rail. Refer to FUEL SYSTEM.
(9) Disconnect the accelerator linkage and, if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the coolant temperature sending
unit wire.
(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 40). Dis-
card the throttle body gasket.
INSTALLATION
(1) If the plenum pan was removed, position pan
gasket and pan.
(2) Install plenum pan retaining bolts. (Fig. 41).
(3) Tighten plenum pan mounting bolts as follows:
²Step 1. Tighten bolts to 5.4 N´m (24 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check all bolts are at 9.5 N´m (84 in.
lbs.)
(4) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N´m
(200 in. lbs.) torque.
(5) Apply a bead of Mopar Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
The sealant bead height should be slightly higher
than the cross-over gaskets, approximately 5 mm (0.2
in). An excessive amount of sealant is not required to
ensure a leak proof seal, and an excessive amount of
sealant may reduce the effectiveness of the flange
gasket.
(6) Install the front and rear cross-over gaskets
onto the engine (Fig. 42).
(7) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 43). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(8) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. long studs
at the front and rear of the manifold will help to
align the intake manifold. After intake manifold is in
Fig. 40 Throttle Body Assembly
1 ± FUEL RAIL ASSEMBLY
2 ± FUEL RAIL MOUNTING BOLTS
3 ± FUEL RAIL CONNECTING HOSES
Fig. 41 Plenum Pan Bolt Tightening Sequence
DN5.9L ENGINE 9 - 163
REMOVAL AND INSTALLATION (Continued)