crankshaft seal DODGE DURANGO 1997 1.G Owner's Manual

Downloaded from www.Manualslib.com manuals search engine CRANKSHAFT OIL SEALÐREAR
REMOVAL
NOTE: This procedure can be preformed in vehicle.(1) If being preformed in vehicle, remove the
transmission. Refer to Group 21, Transmission and
Transfer Case.
(2) Remove the flexplate. Refer to procedure in
this section.
NOTE: The crankshaft oil seal CAN NOT be reused
after removal.
NOTE: The crankshaft rear oil seal remover Special
Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Using Special Tool 8506 (Fig. 132), remove the
crankshaft rear oil seal.
INSTALLATION
(1) Position the magnetic seal guide Special Tool
8349±2 (Fig. 133) onto the crankshaft rear face. Then
position the crankshaft rear oil seal onto the guide.
(2) Using Special Tools 8349 Crankshaft Rear Oil
Seal Installer and C-4171 Driver Handle (Fig. 134),
with a hammer, tap the seal into place. Continue to
tap on the driver handle until the seal installer seats
against the cylinder block crankshaft bore.
(3) Install the flexplate.
(4) If removed, install the transmission.
Fig. 130 Proper Assembly Method for Special Tool
8512
1 ± BEARING
2 ± NUT
3 ± THREADED ROD
4 ± BEARING HARDENED SURFACE (FACING NUT)
5 ± HARDENED WASHER
Fig. 131 Crankshaft DamperÐInstallation
1 ± SPECIAL TOOL 8512
Fig. 132 Crankshaft Rear Oil Seal Removal
1 ± REAR CRANKSHAFT SEAL
2 ± SPECIAL TOOL 8506
DN4.7L ENGINE 9 - 73
REMOVAL AND INSTALLATION (Continued)

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 PISTON AND CONNECTING ROD
CLEANING
CAUTION: DO NOT use a wire wheel or other abra-
sive cleaning devise to clean the pistons or con-
necting rods. The pistons have a Moly coating, this
coating must not be damaged.
(1) Using a suitable cleaning solvent clean the pis-
tons in warm water and towel dry.
(2) Use a wood or plastic scraper to clean the ring
land grooves.
CAUTION: DO NOT remove the piston pin from the
piston and connecting rod assembly.
INSPECTION
Check the crankshaft connecting rod journal for
excessive wear, taper and scoring.
Check the pistons for taper and elliptical shape
before they are fitted into the cylinder bore.
Replace any piston and connecting rod not meeting
the specifications.
OIL PAN
CLEANING
(1) Clean oil pan in solvent and wipe dry with a
clean cloth.
(2) Clean the oil pan gasket surface.DO NOTuse
a grinder wheel or other abrasive tool to clean seal-
ing surface.
(3) Clean oil screen and tube thoroughly in clean
solvent.
INSPECTION
(1) Inspect oil drain plug and plug hole for
stripped or damaged threads. Repair as necessary.
(2) Inspect the oil pan mounting flange for bends
or distortion. Straighten flange, if necessary.
OIL PUMP
CLEANING
(1) Wash all parts in a suitable solvent.
INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump. If
the these components are disassembled andùr
removed from the pump the entire oil pump assem-
bly must be replaced.(1) Clean all parts thoroughly. Mating surface of
the oil pump housing should be smooth. If the pump
cover is scratched or grooved the oil pump assembly
should be replaced.
(2) Lay a straight edge across the pump cover sur-
face (Fig. 137). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between the cover and the straight
edge the oil pump assembly should be replaced.
(3) Measure the thickness of the outer rotor (Fig.
138). If the outer rotor thickness measures at 12.005
mm (0.400 in.) or less the oil pump assembly must be
replaced.
(4) Measure the diameter of the outer rotor. If the
outer rotor diameter measures at 85.925 mm (0.400
in.) or less the oil pump assembly must be replaced.
(5) Measure the thickness of the inner rotor (Fig.
139). If the inner rotor thickness measures at 12.005
mm (0.400 in.) or less then the oil pump assembly
must be replaced.
(6) Slide outer rotor into the body of the oil pump.
Press the outer rotor to one side of the oil pump body
and measure clearance between the outer rotor and
the body (Fig. 140). If the measurement is 0.47mm
(0.0186 in.) or more the oil pump assembly must be
replaced.
(7) Install the inner rotor in the into the oil pump
body. Measure the clearance between the inner and
outer rotors (Fig. 141). If the clearance between the
rotors is .150 mm (0.006 in.) or more the oil pump
assembly must be replaced.
(8) Place a straight edge across the body of the oil
pump (between the bolt holes), if a feeler gauge of
.095 mm (0.0038 in.) or greater can be inserted
between the straightedge and the rotors, the pump
must be replaced (Fig. 142).
NOTE: 4.7 Oil pump is released as an assembly.
There are no DaimlerChrysler part numbers for Sub-
Assembly components. In the event the oil pump is
not functioning or out of specification it must be
replaced as an assembly.
CYLINDER BLOCK
CLEANING
Thoroughly clean the oil pan and engine block gas-
ket surfaces.
Use compressed air to clean out:
²The galley at the oil filter adaptor hole.
²The front and rear oil galley holes.
²The feed holes for the crankshaft main bearings.
Once the block has been completely cleaned, apply
Loctite PST pipe sealant with Teflon 592 to the
threads of the front and rear oil galley plugs. Tighten
the plugs to 34 N´m (25 ft. lbs.) torque.
9 - 76 4.7L ENGINEDN
CLEANING AND INSPECTION (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 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 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)

Downloaded from www.Manualslib.com manuals search engine CRANKSHAFT MAIN BEARINGS
DESCRIPTION
Main bearings are located in the cylinder block.
One half of the main bearing is located in the crank-
shaft main bore the other half of the matching bear-
ing is located in the main bearing cap (Fig. 9). There
are five main bearings. Number three main bearing
is flanged, this flange controls crankshaft thrust.
OPERATION
The main bearings encircle the crankshaft main
bearing journals, this aligns the crankshaft to the
centerline of the engine and allows the crankshaft to
turn without wobbling or shaking therefore eliminat-
ing vibration. The main bearings are available in
standard and undersizes.
CRANKSHAFT
DESCRIPTION
The crankshaft is of a cast nodular steel splayed
type design, with five main bearing journals. The
crankshaft is located at the bottom of the engine
block and is held in place with five main bearing
caps. The number 3 counterweight is the location for
journal size identification (Fig. 10).
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
SERVICE PROCEDURES
FORM-IN-PLACE GASKETS
There are several places where form-in-place gas-
kets are used on the engine.DO NOT use form-in-place gasket material unless specified.Care
must be taken when applying form-in-place gaskets.
Bead size, continuity and location are of great impor-
tance. Too thin a bead can result in leakage while too
much can result in spill-over. A continuous bead of
the proper width is essential to obtain a leak-free
joint.
Two types of form-in-place gasket materials are
used in the engine area (Mopar Silicone Rubber
Adhesive Sealant and Mopar Gasket Maker). Each
have different properties and cannot be used inter-
changeably.
MOPAR SILICONE RUBBER ADHESIVE SEALANT
Mopar Silicone Rubber Adhesive Sealant, normally
black in color, is available in 3 ounce tubes. Moisture
in the air causes the sealant material to cure. This
material is normally used on flexible metal flanges.
It has a shelf life of a year and will not properly cure
if over aged. Always inspect the package for the expi-
ration date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normally red in color, is
available in 6 cc tubes. This anaerobic type gasket
material cures in the absence of air when squeezed
between smooth machined metallic surfaces. It will
not cure if left in the uncovered tube. DO NOT use
on flexible metal flanges.
SURFACE PREPARATION
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some
instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
Fig. 9 Main Bearing Orientation
Fig. 10 Crankshaft with Journal Size Identification
DN5.2L ENGINE 9 - 91
DESCRIPTION AND OPERATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (4) When filter separates from adapter nipple, tip
gasket end upward to minimize oil spill. Remove fil-
ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface (Fig. 15) of oil and grime.
OIL FILTER INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 15) hand
tighten filter one full turn, do not over tighten.
(3) Add oil, verify crankcase oil level and start
engine. Inspect for oil leaks.
REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
CYLINDER BOREÐHONING
Before honing, stuff plenty of clean shop towels
under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 50É to 60É
for proper seating of rings (Fig. 16).
Fig. 14 Oil Filter RemovalÐTypical
1 ± ENGINE OIL FILTER
2 ± OIL FILTER WRENCH
Fig. 15 Oil Filter Sealing SurfaceÐTypical
1 ± SEALING SURFACE
2 ± RUBBER GASKET
3 ± OIL FILTER
Fig. 16 Cylinder Bore Crosshatch Pattern
1 ± CROSSHATCH PATTERN
2 ± INTERSECT ANGLE
9 - 94 5.2L ENGINEDN
SERVICE PROCEDURES (Continued)