vehicle 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 firing order is 1±8±4±3±6±5±7±2. The engine serial
number is located at the right front side of the
engine block (Fig. 1)
ENGINE LUBRICATION SYSTEM
DESCRIPTION
The lubrication system (Fig. 2) is a full flow filtra-
tion pressure feed type.
OPERATION
Oil from the oil pan is pumped by a gerotor type oil
pump directly mounted to the crankshaft nose. Oil
pressure is controlled by a relief valve mounted
inside the oil pump housing. For lubrication flow
refer to (Fig. 2).
The camshaft exhaust valve lobes and rocker arms
are lubricated through a small hole in the rocker
arm; oil flows through the lash adjuster then through
the rocker arm and onto the camshaft lobe. Due to
the orentation of the rocker arm, the camshaft intake
lobes are not lubed in the same manner as the
exhaust lobes. The intake lobes are lubed through
internal passages in the camshaft. Oil flows through
a bore in the number 3 camshaft bearing bore, and
as the camshaft turns, a hole in the camshaft aligns
with the hole in the camshaft bore allowing engine
oil to enter the camshaft tube. The oil then exits
through 1.6mm (0.063 in.) holes drilled into theintake lobes, lubricating the lobes and the rocker
arms.
ENGINE LUBRICATION FLOW CHARTÐBLOCK: TABLE 1
FROM TO
Oil Pickup Tube Oil Pump
Oil Pump Oil Filter
Oil Filter Block Main Oil Gallery
Block Main Oil Gallery 1. Crankshaft Main Journal
2. Left Cylinder Head*
3. Right Cylinder Head*
Crankshaft Main Journals Crankshaft Rod Journals
Crankshaft Number One Main Journal 1.Front Timing Chain Idler Shaft
2. Both Secondary Chain Tensioners
Left Cylinder Head See Table 2
Right Cylinder Head See Table 2
* The cylinder head
gaskets have an oil restricter to control oil flow to the cylinder heads.
Fig. 1 Engine Identification Location.
1 ± VEHICLE VIN NUMBER LOCATION
2 ± CYLINDER BLOCK RIGHT HAND SIDE
3 ± CYLINDER BORE #2
DN4.7L ENGINE 9 - 3
DESCRIPTION AND OPERATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODYIntake valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPEExhaust valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
RADIATORHead gasket leaking or cracked
cylinder head or blockRemove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERSHead gasket leaking or crack in
cylinder head or block between
adjacent cylindersRemove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLYStuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wallInspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
ENGINE OIL LEAK INSPECTION
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and
repeat inspection.
(4)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method.
Air Leak Detection Test Method
(1) Disconnect the breather cap to air cleaner hose
at the breather cap end. Cap or plug breather cap
nipple.
(2) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(3) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.(4) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
(5) If the leakage occurs at the rear oil seal area,
refer to the section, Inspection for Rear Seal Area
Leak.
(6) If no leaks are detected, turn off the air supply
and remove the air hose and all plugs and caps.
Install the PCV valve and breather cap hose.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil
DN4.7L ENGINE 9 - 13
DIAGNOSIS AND TESTING (Continued)

Downloaded from www.Manualslib.com manuals search engine filter runoff, and main bearing cap to cylinder
block mating surfaces.
(4) If no leaks are detected, pressurize the crank-
case as outlined in the, Inspection (Engine oil Leaks
in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
REAR SEAL AREA LEAKSÐINSPECTION
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs, oil galley pipe plugs, oil
filter runoff, and main bearing cap to cylinder
block mating surfaces. See Group 9, Engines, for
proper repair procedures of these items.
(4) If no leaks are detected, pressurized the crank-
case as outlined in the section, Inspection (Engine oil
Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible thecrankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled. Refer to the service DiagnosisÐMechani-
cal, under the Oil Leak row, for components
inspections on possible causes and corrections.
(7) After the oil leak root cause and appropriate
corrective action have been identified, Refer to Group
9, EnginesÐCrankshaft Rear Oil Seals, for proper
replacement procedures.
HYDRAULIC LASH ADJUSTER NOISE
DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) Turn engine off and let set for a few minutes
before restarting. Repeat this several times after
engine has reached normal operating temperature.
(4) Low oil pressure.
(5) The oil restrictor in cylinder head gasket or the
oil passage to the cylinder head is plugged with
debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head and cam on camshaft at
base circle. Depress part of rocker arm over adjuster.
Normal adjusters should feel very firm. Spongy
adjusters can be bottomed out easily.
b. Remove suspected lash adjusters, and replace.
c. Before installation, make sure adjusters are at
least partially full of oil. This can be verified by little
or no plunger travel when lash adjuster is depressed.
9 - 14 4.7L ENGINEDN
DIAGNOSIS AND TESTING (Continued)

Downloaded from www.Manualslib.com manuals search engine CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
pressure loss or oil foaming can result.
Inspect engine oil level approximately every 800
kilometers (500 miles). Unless the engine has exhib-
ited loss of oil pressure, run the engine for about five
minutes before checking oil level. Checking engine oil
level on a cold engine is not accurate.
To ensure proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
The acceptable levels are indicated between the ADD
and SAFE marks on the engine oil dipstick.
(1) Position vehicle on level surface.
(2) With engine OFF, allow approximately ten min-
utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Install dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in Maintenance Schedules.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug if
damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
tion.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
ENGINE OIL FILTER CHANGE
FILTER SPECIFICATION
All engines are equipped with a high quality full-
flow, disposable type oil filter. DaimlerChrysler Cor-
poration recommends a Mopar or equivalent oil filter
be used.OIL FILTER REMOVAL
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise (Fig. 7) to
remove it from the cylinder block oil filter boss.
(4) When filter separates from cylinder block oil
filter boss, tip gasket end upward to minimize oil
spill. Remove filter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface of oil and grime.
OIL FILTER INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 8) hand
tighten filter one full turn, do not over tighten.
(3) Add oil, verify crankcase oil level and start
engine. Inspect for oil leaks.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used
engine oil after it has been drained from a vehicle
engine. Refer to the WARNING at beginning of this
section.REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Fig. 7 Oil FilterÐ4.7L Engine
1 ± ENGINE OIL FILTER
DN4.7L ENGINE 9 - 17
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine (6) Identify the fluid in the cylinders (i.e. coolant,
fuel, oil, etc.).
(7) Make sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt engine oil into the cylinders to lubricate
the walls. This will prevent damage on restart.
(10) Install new spark plugs.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil.
(15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.
VALVE SERVICE
REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
NOTE: When refacing valves and valve seats, it is
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Using a suitable dial indicator measure the
center of the valve seat Total run out must not
exceed 0.051 mm (0.002 in).
(2) Apply a small amount of Prussian blue to the
valve seat, insert the valve into the cylinder head,
while applying light pressure on the valve rotate the
valve. Remove the valve and examine the valve face.
If the blue is transferred below the top edge of the
valve face, lower the valve seat using a 15 degree
stone. If the blue is transferred to the bottom edge of
the valve face, raise the valve seat using a 65 degree
stone.
(3) When the seat is properly positioned the width
of the intake seat must be 1.75 ± 2.36 mm (0.0689 ±
0.0928 in.) and the exhaust seat must be 1.71 ± 2.32
mm (0.0673 ± 0.0911 in.).
(4) Check the valve spring installed height after
refacing the valve and seat. The installed height for
both intake and exhaust valve springs must not
exceed 41.44 mm (1.6315 in.).
(5) The valve seat and valve face must maintain a
face angle of 44.5 ± 45 degrees angle.
ENGINE TIMINGÐVERIFICATION
CAUTION: The 4.7L is a non free-wheeling design
engine. Therefore, correct engine timing is critical.
NOTE: Components referred to as left hand or right
hand are as viewed from the drivers position inside
the vehicle.
NOTE: The blue link plates on the chains and the
dots on the camshaft drive sprockets may not line
up during the timing verification procedure. The
blue link plates are lined up with the sprocket dots
only when re-timing the complete timing drive.
Once the timing drive is rotated blue link-to-dot
alignment is no longer valid.
Engine base timing can be verified by the following
procedure:
(1) Remove the cylinder head covers. Refer to the
procedure in this section.
(2) Using a mirror, locate the TDC arrow on the
front cover (Fig. 11). Rotate the crankshaft until the
mark on the crankshaft damper is aligned with the
TDC arrow on the front cover. The engine is now at
TDC.
Fig. 10 Valve Assembly Configuration
1 ± VALVE LOCKS (3±BEAD)
2 ± RETAINER
3 ± VALVE STEM OIL SEAL
4 ± INTAKE VALVE
5 ± EXHAUST VALVE
6 ± VALVE SPRING
DN4.7L ENGINE 9 - 19
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine nal diameter specification (Main Bearing Fitting
Chart). Select inserts required to obtain the specified
bearing-to-journal clearance.
Install the crankshaft into the cylinder block. Refer
to Crankshaft in this section for procedure.
CRANKSHAFT MAIN BEARING SELECTION
(1) Service main bearings are available in three
grades. The chart below identifies the three service
grades available.
REMOVAL AND INSTALLATION
ENGINE MOUNTSÐLEFT AND RIGHT
REMOVAL
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the fan blade, fan clutch and
fan shroud before raising engine. Failure to do so
may cause damage to the fan blade, fan clutch and
fan shroud.
(2) Remove the fan blade, fan clutch and fan
shroud. Refer to Group 7. for procedure.
(3) Remove the engine oil filter.
(4) Support the engine with a suitable jack and a
block of wood across the full width of the engine oil
pan.
(5) Remove the four (4) cylinder block-to-insulator
mount bolts and the nut from the engine insulator
mount through bolt (4x2 Vehicles only) (Fig. 32) (Fig.
33).
(6) Remove the three (3) cylinder block-to-insulator
mount bolts and loosen the nut from the engine insu-
lator mount through bolt (4x4 Vehicles only) (Fig. 34)
(Fig. 35).
(7) Using the jack, raise the engine high enough to
remove the engine insulator mount through bolt and
the insulator mount.
INSTALLATION
(1) Position the insulator mount and install the
insulator mount through bolt.
(2) Lower the engine until the four cylinder block-
to-insulator mount bolts can be installed.
(3) Remove the jack and block of wood.
(4) Torque the cylinder block-to-insulator mount
bolts to 61N´m ( 45 ft. lbs.).
(5) Install and torque the through bolt retaining
nut to 61N´m (45 ft. lbs.).
(6) Install the fan blade, fan clutch and fan
shroud.
GRADE SIZE mm
(in.)FOR USE WITH
MARKING JOURNAL SIZE
A.008 mm U/S 63.488-63.496 mm
(.0004 in.)
U/S(2.4996-2.4999 in.)
BSTANDARD 63.496-63.504 mm
(2.4996-2.4999 in.)
C.008 mm O/S 63.504-63.512 mm
(.0004 in.)
O/S(2.5002-2.5005 in.)
Fig. 32 Engine Insulator Mount 4x2 VehicleÐLeft
Side
1 ± ENGINE INSULATOR MOUNT-LEFT SIDE
2 ± MOUNTING BOLT
Fig. 33 Engine Insulator Mount 4x2 VehicleÐRight
Side
1 ± ENGINE INSULATOR MOUNT-RIGHT SIDE
2 ± MOUNTING BOLT
9 - 28 4.7L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine ENGINE MOUNTÐREAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Using a suitable jack, support transmission.
(3) Remove the nut from the insulator mount
through bolt (Manual transmission and 4x2 auto-
matic transmission only) (Fig. 36) (Fig. 37).(4) Remove the four bolts and washers retaining
the mount to the transmission (4x4 automatic trans-
mission only) (Fig. 38).
(5) Raise the transmission enough to remove the
through bolt (Manual transmission and 4x2 auto-
matic transmission only) (Fig. 36) (Fig. 37).
(6) Raise the transmission and remove the bolts
retaining the mount to the crossmember (4x4 auto-
matic transmission only) (Fig. 38).
(7) Remove the two nuts retaining the isolator to
the crossmember (Manual transmission and 4x2
automatic transmission only) (Fig. 36) (Fig. 37).
(8) Remove the bolts (two bolts manual transmis-
sion)(three bolts 4x2 automatic transmission) retain-
ing the insulator bracket to the transmission.
INSTALLATION
(1) Follow the removal procedure in the reverse
order.
(2) Tighten the through bolt retaining nut to 102
N´m (75 ft. lbs.).
(3) Tighten the isolator bracket to transmission
retaining bolts (Manual transmission and 4x2 auto-
matic transmission only) to 41 N´m (30 ft. lbs.).
(4) Tighten the mount bracket to transmission
retaining bolts (4x4 automatic transmission only) to
68 N´m (50 ft. lbs.).
(5) Tighten the isolator mount to crossmember
retaining nuts (Manual transmission and 4x2 auto-
matic transmission only) to 28 N´m (250 in. lbs.).
Fig. 34 Engine Insulator Mount 4x4 VehicleÐLeft
Side
1 ± ENGINE INSULATOR MOUNT-LEFT SIDE
2 ± MOUNTING BOLT
Fig. 35 Engine Insulator Mount 4x4 VehicleÐRight
Side
1 ± ENGINE INSULATOR MOUNT-RIGHT SIDE
2 ± MOUNTING BOLT
Fig. 36 Engine Rear MountÐ4X2 Automatic
Transmission
1 ± ENGINE REAR MOUNT
2 ± BOLT
3 ± NUT
4 ± THROUGH BOLT NUT
5 ± TRANSMISSION
DN4.7L ENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (6) Tighten the mount bracket to crossmember
retaining bolts (4x4 automatic transmission only) to
28 N´m (250 in. lbs.).
STRUCTURAL COVER
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the left hand exhaust pipe from
exhaust manifold. Refer to Group 11, Exhaust Sys-
tem.
(3) Loosen the right hand exhaust manifold-to-ex-
haust pipe retaining bolts.
(4) Remove the eight bolts retaining structural
cover (Fig. 39).
(5) Pivot the exhaust pipe downward and remove
the structural cover.
INSTALLATION
CAUTION: The structural cover must be installed
as described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Position the structural cover in the vehicle.
(2) Install all four bolts retaining the cover-to-en-
gine. DO NOT tighten the bolts at this time.
(3) Install the four cover-to-transmission bolts. Do
NOT tighten at this time.
CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starting with the two rear cover-to-engine
bolts, tighten bolts (1) (Fig. 39) to 54 N´m (40 ft. lbs.),
then tighten bolts (2) (Fig. 39) and (3) to 54 N´m ( 40
ft. lbs.) in the sequence shown.
(5) Install the exhaust pipe on left hand exhaust
manifold.
(6) Tighten exhaust manifold-to-exhaust pipe
retaining bolts to 20±26 N´m (15±20 ft. lbs.).
Fig. 37 Engine Rear MountÐ4X2 and 4X4 Manual
Transmission
1 ± THROUGH BOLT
2 ± BOLT
3 ± INSULATOR SUPPORT
4 ± NUT
5 ± NUT AND WASHER
6 ± INSULATOR BRACKET TO TRANSMISSION
Fig. 38 Engine Rear MountÐ4X4 Automatic
Transmission
1 ± TRANSMISSION
2 ± ENGINE REAR MOUNT
3 ± BOLT
Fig. 39 Structural Cover
9 - 30 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine ENGINE ASSEMBLY
REMOVAL
NOTE: This procedure applies to both the 4X2 and
4X4 vehicles, steps that apply to the 4X4 vehicle
only, are identified.
(1) Disconnect the battery negative and positive
cables.
(2) Remove the battery and the battery tray. Refer
to BATTERY.
(3) Raise vehicle on hoist.
(4) Remove exhaust crossover pipe from exhaust
manifolds. Refer to EXHAUST SYSTEM.
(5)4X4 vehiclesDisconnect axle vent tube from
left side engine mount.
(6) Remove the through bolt retaining nut and bolt
from both the left and right side engine mounts (Fig.
40) (Fig. 41).
(7)4X4 vehiclesRemove locknut from left and
right side engine mount brackets (Fig. 41).
(8) Disconnect two ground straps from the lower
left hand side and one ground strap from the lower
right hand side of the engine.
(9) Disconnect crankshaft position sensor. (Fig. 43)
NOTE: The following step applies to 4X4 vehicles
equipped with automatic transmission only.
(10)4X4 vehiclesRemove the axle isolator
bracket from the engine, transmission and the axle
(Fig. 42).
(11) Remove structural cover. Refer to Structural
Cover in this section for procedure.
(12) Remove starter. Refer to STARTING SYS-
TEM.
(13) Drain cooling system. Refer to COOLING
SYSTEM.
(14) Remove torque converter bolts (Automatic
Transmission Only). Refer to TRANSMISSION.
(15) Remove transmission to engine mounting
bolts.
(16) Disconnect the engine block heater power
cable from the block heater, if equipped.(17) Lower vehicle.
(18) Remove throttle body resonator assembly and
air inlet hose.
(19) Disconnect throttle and speed control cables.
(20) Disconnect tube from both the left and right
side crankcase breathers (Fig. 44). Remove breathers
(21) Discharge A/C system. Refer to HEATING and
AIR CONDITIONING.
(22) Remove A/C compressor.
(23) Remove shroud, fan assemblies and accessory
drive belt. Refer to COOLING SYSTEM.
(24) Disconnect transmission oil cooler lines at the
radiator.
(25) Disconnect radiator upper and lower hoses.
Refer to COOLING SYSTEM.
(26) Remove radiator, A/C condenser and transmis-
sion oil cooler as an assembly. Refer to COOLING
SYSTEM.
(27) Remove generator.
(28) Disconnect the two heater hoses from the tim-
ing chain cover and heater core.
(29) Unclip and remove heater hoses and tubes
from the intake manifold (Fig. 45).
(30) Disconnect engine harness at the following
points :
²Intake air temperature (IAT) sensor (Fig. 46)
²Fuel Injectors
SEQUENCE ITEM TORQUE
1BOLT 54 N´m
(Qty 4) (40 ft. lbs.)
2BOLT 54 N´m
(Qty 2) (40 ft. lbs.)
3BOLT 54 N´m
(Qty 2) (40 ft. lbs.)
Fig. 40 Engine Mount Through Bolt and Nut
Removal / InstallationÐ4X2 Vehicles
1 ± LOCKNUT AND WASHER
2 ± ENGINE MOUNT/INSULATOR
3 ± THROUGH BOLT
4 ± FRAME
DN4.7L ENGINE 9 - 31
REMOVAL AND INSTALLATION (Continued)