DODGE DURANGO 1999 1.G Manual Online

Downloaded from www.Manualslib.com manuals search engine DESCRIPTION SPECIFICATION
OIL PUMP
Clearance Over Rotors
(MAX).035 -.095 mm
(0.0014 - 0.0038 in.)
Cover Out - of -Flat
(MAX).025 mm (0.001 in.)
Inner and Outer Rotor
Thickness 12.08 mm (0.4756 in.)
Outer Rotor Clearance
(MAX)85.96 mm (3.3843 in.)
Outer Rotor Diameter
(MIN)85.925 mm (0.400 in.)
Tip Clearance Between
Rotors
(MAX) .150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed
(MIN)*25 kPa (4 psi)
@ 3000 rpm 170 - 550 kPa (25 - 80
psi)
* CAUTION: If pressure is zero at curb idle, DO
NOT run engine at 3000 rpm.
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90 Ð
Bearing Cap Bolts 11 Ð 100
Timing Chain CoverÐBolts 54 40 Ð
Connecting Rod CapÐBolts 27 20 Ð
PLUS 90É TURN
Bed PlateÐBolts Refer to Procedure
Crankshaft DamperÐBolt 175 130 Ð
Cylinder HeadÐBolts
M11 Bolts 81 60 Ð
M8 Bolts 28 Ð 250
Cylinder Head CoverÐBolts 12 Ð 105
Exhaust ManifoldÐBolts 25 18 Ð
Exhaust Manifold Heat
ShieldÐNuts8Ð72
Then loosen 45É
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
FlexplateÐBolts 60 45 Ð
Engine Mount Bracket to
BlockÐBolts61 45 Ð
Rear Mount to
TransmissionÐBolts46 34 Ð
Generator MountingÐBolts
M10 Bolts 54 40 Ð
M8 Bolts 28 Ð 250
Intake ManifoldÐBolts 12 Ð 105
Refer to Procedure
for
Tightening Sequence
Oil PanÐBolts 15 Ð 130
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐBolts 28 Ð 250
Oil Pump CoverÐBolts 12 Ð 105
Oil Pickup TubeÐBolt and
Nut28 Ð 250
Oil Dipstick TubeÐBolt 28 Ð 250
Oil Fill TubeÐBolts 12 Ð 105
Timing Chain GuideÐBolts 28 Ð 250
Timing Chain Tensioner
ArmÐSpecial
Pin Bolt 17 Ð 150
Hydraulic TensionerÐBolts 28 Ð 250
Timing Chain Primary
TensionerÐBolts28 Ð 250
Timing Drive Idler SprocketÐ
Bolt34 25 Ð
Thermostat HousingÐBolts 12 Ð 105
Water PumpÐBolts 54 40 Ð
DN4.7L ENGINE 9 - 81
SPECIFICATIONS (Continued)

Downloaded from www.Manualslib.com manuals search engine SPECIAL TOOLS
4.7L ENGINE
Spanner Wrench 6958
Adapter Pins 8346
Engine Lifting Studs 8400
Engine Lift Fixture 8347
Front Crankshaft Seal Remover 8511
Front Crankshaft Seal Installer 8348
Handle C-4171
Rear Crankshaft Seal Installer 8349
9 - 82 4.7L ENGINEDN

Downloaded from www.Manualslib.com manuals search engine Rear Crankshaft Seal Remover 8506
Connecting Rod Guides 8507
Crankshaft Damper Installer 8512
Puller 1026
Crankshaft Damper Removal Insert 8513
Chain Tensioner Wedge 8350
Chain Tensioner Pins 8514
Secondary Chain Holder 8515
DN4.7L ENGINE 9 - 83
SPECIAL TOOLS (Continued)

Downloaded from www.Manualslib.com manuals search engine Remover, Rocker Arm 8516
Valve Spring Compressor 8387
Idler Shaft Remover 8517
Valve Spring Compressor Adapters 8519
Valve Spring Tester C-647
Dial Indicator C-3339
Valve Spring Compressor C-3422-B
Bore Size Indicator C-119
Oil Pressure Gauge C-3292
9 - 84 4.7L ENGINEDN
SPECIAL TOOLS (Continued)

Downloaded from www.Manualslib.com manuals search engine Piston Ring Compressor C-385
Pressure Tester Kit 7700
Bloc±Chek±Kit C-3685±A
DN4.7L ENGINE 9 - 85
SPECIAL TOOLS (Continued)

Downloaded from www.Manualslib.com manuals search engine 5.2L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ENGINE................................86
ENGINE LUBRICATION SYSTEM.............87
EXHAUST MANIFOLD.....................89
INTAKE MANIFOLD.......................89
CYLINDER HEAD COVER GASKET...........90
CYLINDER HEAD.........................90
VALVES AND VALVE SPRINGS..............90
ENGINE OIL PAN.........................90
CRANKSHAFT OIL SEALS..................90
PISTON AND CONNECTING ROD............90
CRANKSHAFT MAIN BEARINGS.............91
CRANKSHAFT...........................91
SERVICE PROCEDURES
FORM-IN-PLACE GASKETS.................91
ENGINE PERFORMANCE..................92
ENGINE OIL.............................92
REPAIR DAMAGED OR WORN THREADS......94
CYLINDER BOREÐHONING................94
HYDROSTATIC LOCK.....................95
VALVE TIMING...........................95
VALVE SERVICE.........................95
MEASURING TIMING CHAIN STRETCH........97
PISTONSÐFITTING.......................98
PISTON RINGSÐFITTING..................98
CONNECTING ROD BEARINGSÐFITTING.....100
CRANKSHAFT MAIN BEARINGSÐFITTING....100
REMOVAL AND INSTALLATION
ENGINE MOUNTSÐFRONT................100
ENGINE MOUNTÐREAR..................102
ENGINE ASSEMBLY......................102
INTAKE MANIFOLD......................103
EXHAUST MANIFOLD....................105
CYLINDER HEAD COVER.................106
ROCKER ARMS AND PUSH RODS..........107
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE.............107CYLINDER HEAD........................107
VALVES AND VALVE SPRINGS.............108
HYDRAULIC TAPPETS....................109
VIBRATION DAMPER.....................109
TIMING CHAIN COVER...................110
TIMING CHAIN..........................111
CAMSHAFT............................111
CAMSHAFT BEARINGS...................113
CRANKSHAFT MAIN BEARINGS............113
DISTRIBUTOR DRIVE SHAFT BUSHING......114
OILPAN...............................115
PISTON AND CONNECTING ROD ASSEMBLY . . 116
CRANKSHAFT..........................116
OIL PUMP.............................117
CRANKSHAFT OIL SEALÐFRONT...........117
CRANKSHAFT OIL SEALSÐREAR...........118
ENGINE CORE OIL AND CAMSHAFT PLUGS . . 120
DISASSEMBLY AND ASSEMBLY
VALVE SERVICE........................121
OIL PUMP.............................123
CYLINDER BLOCK.......................124
CLEANING AND INSPECTION
CYLINDER HEAD COVER.................124
CYLINDER HEAD ASSEMBLY..............124
PISTON AND CONNECTING ROD ASSEMBLY . . 124
OILPAN...............................124
OIL PUMP.............................125
CYLINDER BLOCK.......................127
INTAKE MANIFOLD......................127
EXHAUST MANIFOLD....................127
SPECIFICATIONS
5.2L ENGINE SPECIFICATIONS.............128
TORQUE SPECIFICATIONS................132
SPECIAL TOOLS
5.2L ENGINE...........................132
DESCRIPTION AND OPERATION
ENGINE
DESCRIPTION
The 5.2 Liter (318 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets.
The engine lubrication system consists of a rotor
type oil pump and a full flow oil filter.The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1). This
engine is designed for unleaded fuel.
The engine serial number is stamped into a
machined pad located on the left, front corner of the
cylinder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 2).
9 - 86 5.2L ENGINEDN

Downloaded from www.Manualslib.com manuals search engine ENGINE LUBRICATION SYSTEM
DESCRIPTION
A gear-type positive displacement pump (Fig. 3) is
mounted at the underside of the rear main bearing
cap. The pump uses a pick-up tube and screen
assembly to gather engine oil from the oil pan.
OPERATION
The pump draws oil through the screen and inlet
tube from the sump at the rear of the oil pan. The oil
is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery that
channels the oil up to the main gallery, which
extends the entire length on the right side of the
block. The oil then goes down to the No. 1 main bear-ing, back up to the left side of the block, and into the
oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod
rotates. This oil throwoff lubricates the camshaft
lobes, distributor drive gear, cylinder walls, and pis-
ton pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. The camshaft bearings
receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the cam-
shaft sprocket to the timing chain. Oil drains back to
the oil pan under the No. 1 main bearing cap.
The oil supply for the rocker arms and bridged
pivot assemblies is provided by the hydraulic valve
tappets, which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components.
The oil then passes down through the push rod guide
holes and the oil drain-back passages in the cylinder
head, past the valve tappet area, and then returns to
the oil pan.
Fig. 1 Firing Order
Fig. 2 Engine Identification Number
Fig. 3 Positive Displacement Oil PumpÐTypical
1 ± INNER ROTOR AND SHAFT
2 ± BODY
3 ± DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 ± COTTER PIN
5 ± RETAINER CAP
6 ± SPRING
7 ± RELIEF VALVE
8 ± LARGE CHAMFERED EDGE
9 ± BOLT
10 ± COVER
11 ± OUTER ROTOR
DN5.2L ENGINE 9 - 87
DESCRIPTION AND OPERATION (Continued)

Downloaded from www.Manualslib.com manuals search engine Fig. 4 Oil Lubrication System
9 - 88 5.2L ENGINEDN
DESCRIPTION AND OPERATION (Continued)

Downloaded from www.Manualslib.com manuals search engine EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds are constructed of cast iron
and are LOG type with balanced flow (Fig. 5). One
exhaust manifold is attached to each cylinder head.
OPERATION
The exhaust manifolds collect the engine exhaust
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipes attached to the
manifolds.
INTAKE MANIFOLD
DESCRIPTION
The aluminum intake manifold (Fig. 6) is a single
plane design with equal length runners and uses a
separate plenum, therefore the manifold does have a
plenum gasket. It also uses separate flange gaskets
and front and rear cross-over gaskets. Extreme caremust be used when sealing the gaskets to ensure
that excess sealant does not enter the intake runners
causing a restriction. Whenever the intake manifold
is removed inspect the plenum pan for evidence of
excess oil buildup, this condition indicates that the
plenum pan gasket is leaking.
OPERATION
The intake manifold, meters and delivers air to the
combustion chambers allowing the fuel delivered by
the fuel injectors to ignite, thus producing power.
1 ± OIL DEFLECTOR TAB
2 ± BOLT
3 ± ROCKER ARM PIVOT
4 ± ROCKER ARM
5 ± DRIP OILING FOR VALVE TIP
6 ± CYLINDER HEAD BOSS
7 ± TO MAIN BEARINGS
8 ± TO CAMSHAFT BEARINGS
9 ± ROCKER ARM
10 ± HOLLOW PUSH ROD
11 ± TAPPET
12 ± TO CONNECTING ROD BEARINGS
13 ± OIL INTAKE14 ± OIL PUMP
15 ± OIL FILTER
16 ± CRANKSHAFT
17 ± FROM OIL PUMP
18 ± OIL TO FILTER
19 ± OIL FROM FILTER TO SYSTEM
20 ± PASSAGE TO CAMSHAFT REAR BEARING
21 ± RIGHT OIL GALLERY
22 ± PLUG
23 ± OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT
24 ± OIL SUPPLY VIA HOLLOW PUSH ROD SUPPLY IS FROM
OIL GALLERY METERED THROUGH HYDRAULIC TAPPET
25 ± OIL SUPPLY FROM HOLLOW PUSH ROD
Fig. 5 Exhaust ManifoldsÐV-8 Gas Engines Typical
1 ± EXHAUST MANIFOLD (LEFT)
2 ± BOLTS & WASHERS
3 ± NUTS & WASHERS
4 ± EXHAUST MANIFOLD (RIGHT)
5 ± BOLTS & WASHERS
Fig. 6 Intake Manifold and Throttle BodyÐV-8 Gas
Engines Typical
1 ± FUEL RAIL ASSEMBLY
2 ± FUEL RAIL MOUNTING BOLTS
3 ± FUEL RAIL CONNECTING HOSES
DN5.2L ENGINE 9 - 89
DESCRIPTION AND OPERATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CYLINDER HEAD COVER GASKET
DESCRIPTION
The cylinder head cover gasket is a steel-backed
silicone gasket, designed for long life usage (Fig. 7).
OPERATION
The steel-backed silicone gasket is designed to seal
the cylinder head cover for long periods of time
through extensive heat and cold, without failure. The
gasket is designed to be reusable.
CYLINDER HEAD
DESCRIPTION
The cast iron cylinder heads are mounted to the
cylinder block using ten bolts (Fig. 8). The spark
plugs are located in the peak of the wedge between
the valves.
OPERATION
The cylinder head closes the combustion chamber
allowing the pistons to compress the air fuel mixture
to the correct ratio for ignition. The valves located in
the cylinder head open and close to either allow clean
air into the combustion chamber or to allow the
exhaust gases out, depending on the stroke of the
engine.
VALVES AND VALVE SPRINGS
DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 48.768 mm (1.92 inches) in
diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch)
wafer interia welded to the tip for durability. These
valves are not splayed.
ENGINE OIL PAN
DESCRIPTION
The stamped steel engine oil pan is located at the
bottom of the engine, and contains a drain plug for
draining the engine oil.
OPERATION
The oil pan holds the engine oil and seals and pro-
tects the engine lower components from contami-
nates.
CRANKSHAFT OIL SEALS
DESCRIPTION
The crankshaft rear seal is a two piece viton seal.
The crankshaft front seal is a one piece viton seal
with a steel housing. The front seal is located in the
engine front cover. One part of the two piece rear
seal is located in a slot in the number five (5) crank-
shaft main bore, the second part of the two piece seal
is located in the number five (5) main bearing cap.
OPERATION
The crankshaft seals prevent oil from leaking from
around the crankshaft, either from the rear of the
engine or from the engine front cover.
PISTON AND CONNECTING ROD
DESCRIPTION
The pistons are made of aluminum and have three
ring grooves, the top two grooves are for the compres-
sion rings and the bottom groove is for the oil control
ring. The connecting rods are forged steel and are
coined prior to heat treat. The piston pins are press
fit.
Fig. 7 Cylinder Head Cover Gasket V-8 Gas Engines
1 ± CYLINDER HEAD COVER GASKET
Fig. 8 Cylinder Head AssemblyÐV-8 Gas Engines
1 ± EXHAUST VALVE
2 ± SPARK PLUGS
3 ± EXHAUST VALVES
4 ± SPARK PLUGS
5 ± EXHAUST VALVE
6 ± INTAKE VALVES
7 ± INTAKE VALVES
9 - 90 5.2L ENGINEDN
DESCRIPTION AND OPERATION (Continued)