135 DODGE DURANGO 1998 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine ENGINE
TABLE OF CONTENTS
page page
4.7L ENGINE.............................. 1
5.2L ENGINE............................. 865.9L ENGINE............................ 135
4.7L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ENGINE.................................2
ENGINE LUBRICATION SYSTEM..............3
CYLINDER BLOCK.........................5
CRANKSHAFT............................5
PISTON AND CONNECTING ROD.............5
CYLINDER HEAD..........................5
VALVE GUIDES...........................5
VALVES.................................5
VALVE STEM SEAL........................5
VALVE SPRING...........................6
HYDRAULIC LASH ADJUSTER...............6
TIMING DRIVE SYSTEM....................6
CAMSHAFT..............................6
ROCKER ARM............................6
CYLINDER HEAD COVER...................6
OILPAN.................................7
STRUCTURAL DUST COVER................7
INTAKE MANIFOLD........................7
EXHAUST MANIFOLD......................7
DIAGNOSIS AND TESTING
ENGINE DIAGNOSISÐINTRODUCTION.........7
SERVICE DIAGNOSISÐPERFORMANCE.......8
SERVICE DIAGNOSISÐMECHANICAL.........10
SERVICE DIAGNOSISÐLUBRICATION.........11
INTAKE MANIFOLD LEAKAGE DIAGNOSIS.....11
CYLINDER COMPRESSION PRESSURE TEST . . 11
CYLINDER HEAD GASKET FAILURE
DIAGNOSIS...........................12
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST........................12
ENGINE OIL LEAK INSPECTION.............13
REAR SEAL AREA LEAKSÐINSPECTION......14
HYDRAULIC LASH ADJUSTER NOISE
DIAGNOSIS...........................14
CHECKING ENGINE OIL PRESSURE..........15SERVICE PROCEDURES
FORM-IN-PLACE GASKETS.................15
ENGINE OIL.............................16
REPAIR DAMAGED OR WORN THREADS......17
CYLINDER BOREÐHONING................18
HYDROSTATIC LOCK.....................18
VALVE SERVICE.........................19
ENGINE TIMINGÐVERIFICATION............19
TIMING CHAINÐMEASURING WEAR.........22
PISTONSÐFITTING.......................22
PISTON RINGSÐFITTING..................24
CONNECTING ROD BEARINGSÐFITTING.....25
CRANKSHAFT MAIN BEARINGS.............27
REMOVAL AND INSTALLATION
ENGINE MOUNTSÐLEFT AND RIGHT.........28
ENGINE MOUNTÐREAR...................29
STRUCTURAL COVER.....................30
ENGINE ASSEMBLY.......................31
INTAKE MANIFOLD.......................35
EXHAUST MANIFOLDS....................36
CYLINDER HEAD COVER..................38
ROCKER ARMS..........................40
CYLINDER HEADS........................41
VALVE SPRINGS AND SEALS...............46
HYDRAULIC LASH ADJUSTER..............46
CRANKSHAFT DAMPER...................47
TIMING CHAIN COVER....................48
TIMING CHAIN AND SPROCKETS............49
IDLER SHAFTÐTIMING DRIVE..............55
CAMSHAFTSÐIN VEHICLE.................56
CRANKSHAFT MAIN BEARINGS.............61
OIL PAN 4X2 VEHICLE.....................61
OIL PAN 4X4 VEHICLE.....................64
PISTON AND CONNECTING ROD............65
CRANKSHAFT...........................67
FLEXPLATE.............................69
DNENGINE 9 - 1

Downloaded from www.Manualslib.com manuals search engine ENGINE CORE PLUGS
REMOVAL
(1) Drain the cooling system. Refer to Group 7,
Cooling System for procedure.
(2) Using a blunt tool such as a drift or a screw
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 135).(3) Using a suitable pair of pliers, grasp the core
plug and remove.
INSTALLATION
NOTE: Thoroughly clean core plug bore, remove all
of the old sealer.
(1) Coat the edges of the engine core plug and the
core plug bore with Mopar Gasket Maker, or equiva-
lent.
NOTE: It is not necessary to wait for the sealant to
cure on the core plugs. The cooling system can be
filled and the vehicle returned to service immedi-
ately.
(2) Using proper plug driver, drive core plug into
the core plug bore. The sharp edge of the core plug
should be at least 0.50 mm (0.020 in.) inside the lead
in chamfer.
(3) Refill the cooling system.
DISASSEMBLY AND ASSEMBLY
OIL PUMP
DISASSEMBLE
(1) Remove oil pump cover screws and lift off cover
plate.
(2) Remove pump inner and outer rotors.
Fig. 133 Crankshaft Rear Oil Seal Guide Special
Tool 8349±2 and Oil Seal
1 ± REAR CRANKSHAFT SEAL
2 ± SPECIAL TOOL 8349±2 GUIDE
Fig. 134 Crankshaft Rear Oil Seal Installation
1 ± REAR CRANKSHAFT SEAL
2 ± SPECIAL TOOL 8349±1 INSTALLER
3 ± SPECIAL TOOL C-4171 HANDLE
Fig. 135 Engine Core Plug Removal
1 ± CYLINDER BLOCK
2 ± REMOVE PLUG WITH PLIERS
3 ± STRIKE HERE WITH HAMMER
4 ± DRIFT PUNCH
5 ± CUP PLUG
9 - 74 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine spring seat in cylinder head to the bottom surface of
spring retainer. If spacers are installed, measure
from the top of spacer. If height is greater than 42.86
mm (1-11/16 inches), install a 1.587 mm (1/16 inch)
spacer in head counterbore. This should bring spring
height back to normal 41.27 to 42.86 mm (1-5/8 to
1-11/16 inch).
HYDRAULIC TAPPETS
REMOVAL
(1) Remove the air cleaner assembly and air inlet
hose.
(2) Remove cylinder head cover, rocker assembly
and push rods. Identify push rods to ensure installa-
tion in original location.
(3) Remove intake manifold, yoke retainer and
aligning yokes.
(4) Slide Hydraulic Tappet Remover/Installer Tool
C-4129-A through opening in cylinder head and seat
tool firmly in the head of tappet.
(5) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed, identify tappets to
ensure installation in original location.
INSTALLATION
(1) If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet.
(2) Lubricate tappets.
(3) Install tappets and push rods in their original
positions. Ensure that the oil feed hole in the side of
the tappet body faces up (away from the crankshaft).
(4) Install aligning yokes with ARROW toward
camshaft.
(5) Install yoke retainer. Tighten the bolts to 23
N´m (200 in. lbs.) torque. Install intake manifold.
(6) Install push rods in original positions.
(7) Install rocker arm.
(8) Install cylinder head cover.
(9) Install air cleaner assembly and air inlet hose.
(10) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
VIBRATION DAMPER
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine.(3) Remove the cooling system fan.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove the vibration damper pulley.
(6) Remove vibration damper bolt and washer from
end of crankshaft.
(7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 46).
(8) Pull vibration damper off of the crankshaft.
INSTALLATION
(1) Position the vibration damper onto the crank-
shaft.
(2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 47).
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 183 N´m (135 ft. lbs.) torque.
(4) Install the crankshaft pulley. Tighten the pul-
ley bolts to 23 N´m (200 in. lbs.) torque.
(5) Install the serpentine belt (refer to Group 7,
Cooling System).
(6) Install the cooling system fan. Tighten the
bolts to 23 N´m (17 ft. lbs.) torque.
Fig. 46 Vibration Damper Assembly
1 ± SPECIAL TOOL C-3688
Fig. 47 Installing Vibration Damper
1 ± SPECIAL TOOL C-3688
DN5.2L ENGINE 9 - 109
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine TORQUE SPECIFICATIONS
TORQUE CHART 5.2L ENGINE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 50 Ð
Camshaft Thrust PlateÐBolts 24 Ð 210
Chain Case CoverÐBolts 41 30 Ð
Connecting Rod CapÐBolts 61 45 Ð
Main Bearing CapÐBolts 115 85 Ð
Crankshaft PulleyÐBolts 24 Ð 210
Cylinder HeadÐBolts
Step 1 68 50 Ð
Step 2 143 105 Ð
Cylinder Head CoverÐBolts 11 Ð 95
Engine Support Bracket to
BlockÐ41 30 Ð
Bolts (4WD)
Exhaust Manifold to Cylinder
HeadÐ34 25 Ð
Bolts/Nuts
FlywheelÐBolts 75 55 Ð
Front InsulatorÐThrough
bolt/nut95 70 Ð
Front Insulator to Support
BracketÐ
Stud Nut (4WD) 41 30 Ð
Through Bolt/Nut 102 75 Ð
Front Insulator to BlockÐ 95 70 Ð
Bolts (2WD)
GeneratorÐMounting Bolts 41 30 Ð
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 Ð 215
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐMounting Bolts 41 30 Ð
Oil Pump CoverÐBolts 11 Ð 95
Rear Insulator to BracketÐ
Through68 50 Ð
Bolt (2WD)
Rear Insulator to
Crossmember41 30 Ð
Support BracketÐNut (2WD)
Rear Insulator to
CrossmemberÐ68 50 Ð
Nuts (4WD)
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Rear Insulator to
TransmissionÐ68 50 Ð
Bolts (4WD)
Rear Insulator BracketÐBolts 68 50 Ð
(4WD Automatic)
Rear Support Plate to
Transfer Case41 30 Ð
ÐBolts
Rocker ArmÐBolts 28 21 Ð
Spark Plugs 41 30 Ð
Starter MotorÐMounting
Bolts68 50 Ð
Thermostat HousingÐBolts 25 Ð 225
Throttle BodyÐBolts 23 Ð 200
Torque Converter Drive
PlateÐBolts31 Ð 270
Transfer Case to Insulator
Mounting204 150 Ð
PlateÐNuts
Transmission Support
BracketÐ68 50 Ð
Bolts (2WD)
Vibration DamperÐBolt 183 135 Ð
Water Pump to Timing Chain
Case41 30 Ð
CoverÐBolts
SPECIAL TOOLS
5.2L ENGINE
Oil Pressure Gauge C-3292
9 - 132 5.2L ENGINEDN
SPECIFICATIONS (Continued)

Downloaded from www.Manualslib.com manuals search engine 5.9L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ENGINE...............................136
ENGINE LUBRICATION SYSTEM............136
EXHAUST MANIFOLD....................139
INTAKE MANIFOLD......................139
CYLINDER HEAD COVER GASKET..........140
CYLINDER HEAD........................140
VALVES AND VALVE SPRINGS.............140
ENGINE OIL PAN........................140
CRANKSHAFT OIL SEALS.................140
PISTON AND CONNECTING ROD...........140
CRANKSHAFT MAIN BEARINGS............141
CRANKSHAFT..........................141
DIAGNOSIS AND TESTING
ENGINE DIAGNOSISÐINTRODUCTION.......141
SERVICE DIAGNOSISÐGASOLINE ENGINES . . 142
INTAKE MANIFOLD LEAKAGE DIAGNOSIS....145
CYLINDER COMPRESSION PRESSURE TEST . 145
CYLINDER HEAD GASKET FAILURE
DIAGNOSIS...........................146
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST.......................146
INSPECTION (ENGINE OIL LEAKS IN
GENERAL)...........................147
REAR SEAL AREA LEAKSÐINSPECTION.....147
HYDRAULIC TAPPETS....................148
ENGINE OIL PRESSURE..................148
SERVICE PROCEDURES
FORM-IN-PLACE GASKETS................149
ENGINE PERFORMANCE.................149
ENGINE OIL............................150
REPAIR DAMAGED OR WORN THREADS.....151
CYLINDER BOREÐHONING...............152
HYDROSTATIC LOCK.....................152
VALVE TIMING..........................153
VALVE SERVICE........................153
MEASURING TIMING CHAIN STRETCH.......155
PISTONSÐFITTING......................156
PISTON RINGSÐFITTING.................156
CONNECTING ROD BEARINGSÐFITTING.....157
CRANKSHAFT MAIN BEARINGSÐFITTING....157
REMOVAL AND INSTALLATION
ENGINE FRONT MOUNTS.................158ENGINE REAR SUPPORT.................160
ENGINE ASSEMBLY......................161
INTAKE MANIFOLD......................163
EXHAUST MANIFOLD....................165
CYLINDER HEAD COVER.................165
ROCKER ARMS AND PUSH RODS..........166
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE.............166
CYLINDER HEAD........................167
VALVES AND VALVE SPRINGS.............167
HYDRAULIC TAPPETS....................168
VIBRATION DAMPER.....................168
TIMING CHAIN COVER...................169
TIMING CHAIN..........................170
CAMSHAFT............................170
CAMSHAFT BEARINGS...................172
DISTRIBUTOR DRIVE SHAFT BUSHING......172
CRANKSHAFT MAIN BEARINGS............174
OILPAN...............................174
PISTON AND CONNECTING ROD ASSEMBLY . . 175
CRANKSHAFT..........................176
OIL PUMP.............................177
CRANKSHAFT OIL SEALÐFRONT...........178
CRANKSHAFT OIL SEALSÐREAR...........179
ENGINE CORE OIL AND CAMSHAFT PLUGS . . 180
DISASSEMBLY AND ASSEMBLY
OIL PUMP.............................181
CLEANING AND INSPECTION
CYLINDER HEAD COVER.................182
CYLINDER HEAD ASSEMBLY..............182
PISTON AND CONNECTING ROD ASSEMBLY . . 182
OILPAN...............................182
OIL PUMP.............................182
CYLINDER BLOCK.......................185
INTAKE MANIFOLD......................185
EXHAUST MANIFOLD....................185
SPECIFICATIONS
5.9L ENGINE SPECIFICATIONS.............185
SPECIFICATIONS........................189
SPECIAL TOOLS
5.9L ENGINE...........................189
DN5.9L ENGINE 9 - 135