cooling system DODGE DURANGO 1998 1.G User Guide

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
(1) Install hydraulic lash adjuster making sure
adjusters are at least partially full of oil. This can be
verified by little or no plunger travel when lash
adjuster is depressed.
(2) Install rocker arm(s). Refer to procedure in this
section.
(3) Install cylinder head cover(s). Refer to proce-
dure in this section.
CRANKSHAFT DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt. Refer to COOL-
ING SYSTEM.
(3) Drain cooling system. Refer to COOLING SYS-
TEM.
(4) Remove radiator upper hose.
(5) Remove upper fan shroud. Refer to COOLING
SYSTEM.
(6) Using Special Tools 6958 Spanner with Adapter
Pins 8346, loosen fan and viscous assembly from
water pump (Fig. 69).
(7) Remove fan and viscous assembly.
(8) Disconnect electrical connector for fan mounted
inside radiator shroud.NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
(9) Remove crankshaft damper bolt.
(10) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 70).
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Align crankshaft damper slot with key in
crankshaft. Slide damper onto crankshaft slightly.
CAUTION: Special Tool 8512, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
(2) Assemble Special Tool 8512 as follows, The nut
is threaded onto the shaft first. Then the roller bear-
ing is placed onto the threaded rod (The hardened
bearing surface of the bearingMUSTface the nut).
Then the hardened washer slides onto the threaded
rod (Fig. 71). Once assembled coat the threaded rod's
threads with MopartNickel Anti-Seize or (Loctite
No. 771).
Fig. 68 Valve Assembly Configuration
1 ± VALVE LOCKS (3±BEAD)
2 ± RETAINER
3 ± VALVE STEM OIL SEAL
4 ± INTAKE VALVE
5 ± EXHAUST VALVE
6 ± VALVE SPRINGFig. 69 Fan AssemblyÐRemoval/Installation
1 ± SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2±FAN
DN4.7L ENGINE 9 - 47
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (3) Using Special Tool 8512, press damper onto
crankshaft (Fig. 72).
(4) Install then tighten crankshaft damper bolt to
175 N´m (130 ft. lbs.).
(5) Install fan blade assembly.(6) Install radiator upper shroud and tighten fas-
teners to 11 N´m (95 in. lbs.).
(7) Connect electrical connector for shroud fan.
(8) Install radiator upper hose.
(9) Install accessory drive belt.
(10) Refill cooling system.
(11) Connect negative cable to battery.
TIMING CHAIN COVER
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system and remove viscous fan
drive assembly. Refer to Group 7, Cooling System for
procedures.
(3) Remove radiator shroud. Refer to Group 7,
Cooling System for procedure.
(4) Disconnect both heater hoses at timing cover.
(5) Disconnect lower radiator hose at engine.
(6) Remove crankshaft damper. Refer to procedure
in this section.
(7) Remove accessory drive belt tensioner assembly
(Fig. 73).
(8) Remove the generator and A/C compressor.
(9) Remove cover and gasket (Fig. 74).
INSTALLATION
(1) Clean timing chain cover and block surface.
Inspect cover gasket and replace as necessary.
(2) Install cover and gasket. Tighten fasteners in
sequence as shown in (Fig. 74) to 54 N´m (40 ft. lbs.).
Fig. 70 Crankshaft DamperÐRemoval
1 ± SPECIAL TOOL 8513 INSERT
2 ± SPECIAL TOOL 1026
Fig. 71 Proper Assembly Method for Special Tool
8512
1 ± BEARING
2 ± NUT
3 ± THREADED ROD
4 ± BEARING HARDENED SURFACE (FACING NUT)
5 ± HARDENED WASHER
Fig. 72 Crankshaft DamperÐInstallation
1 ± SPECIAL TOOL 8512
9 - 48 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (3) Install the A/C compressor and generator.
(4) Install crankshaft damper. Refer to procedure
in this section.
(5) Install accessory drive belt tensioner assembly.
Tighten fastener to 54 N´m (40 ft. lbs.).
(6) Install lower radiator hose.
(7) Install both heater hoses.
(8) Install radiator shroud and viscous fan drive
assembly. Refer to Group 7, Cooling System for pro-
cedure.(9) Fill cooling system. Refer to Group 7, Cooling
System for procedures.
(10) Connect the battery negative cable.
TIMING CHAIN AND SPROCKETS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. Refer to Group 7, Cooling
System for procedures.
(3) Remove right and left cylinder head covers.
Refer to procedure in this section.
(4) Remove radiator fan shroud. Refer to Group 7,
Cooling System for procedure.
(5) Rotate engine until timing mark on crankshaft
damper aligns with TDC mark on timing chain cover
(Fig. 75) (#1 cylinder exhaust stroke) and the cam-
shaft sprocket ªV8º marks are at the 12 o'clock posi-
tion (Fig. 76).
(6) Remove power steering pump. Refer to Group
19, Steering for procedures.
(7) Remove access plugs (2) from left and right cyl-
inder heads for access to chain guide fasteners (Fig.
77).
(8) Remove the oil fill housing to gain access to the
right side tensioner arm fastener.
(9) Remove crankshaft damper and timing chain
cover. Refer to procedures in this section.
Fig. 73 Accessory Drive Belt Tensioner
1 ± TENSIONER ASSEMBLY
2 ± FASTENER TENSIONER TO FRONT COVER
Fig. 74 Timing Chain Cover Fasteners
Fig. 75 Engine Top Dead Center (TDC) Indicator
Mark
1 ± TIMING CHAIN COVER
2 ± CRANKSHAFT TIMING MARKS
DN4.7L ENGINE 9 - 49
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (24) Coat the large threaded access plug with
MopartThread Sealant with Teflon, then install
into the right cylinder head and tighten to 81 N´m
(60 ft. lbs.) (Fig. 77).(25) Install the oil fill housing.
(26) Install access plug in left cylinder head (Fig.
77).
(27) Install power steering pump. Refer to Group
19, Steering for procedure.
(28) Install radiator fan shroud. Refer to Group 7,
Cooling System for procedure.
(29) Fill cooling system. Refer to Group 7, Cooling
System for coolant fill procedure.
(30) Connect negative cable to battery.
IDLER SHAFTÐTIMING DRIVE
REMOVAL
(1) Remove the timing chain and sprockets. Refer
to procedure in this section.
NOTE: To remove the idler shaft, it is necessary to
tap threads into the shaft to install the removal tool.
(2) Using a 12 mm X 1.75 tap, cut threads in the
idler shaft center bore (Fig. 89).
(3) Cover the radiator core with a suitable cover.
CAUTION: Use care when removing idler shaft, DO
NOT strike the radiator cooling fins with the slide
hammer.
(4) Using Special Tool 8517 Slide Hammer, remove
the idler shaft (Fig. 90).
Fig. 87 Tightening Right Side Camshaft Sprocket
Bolt
1 ± TORQUE WRENCH
2 ± SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 ± LEFT CAMSHAFT SPROCKET
4 ± RIGHT CAMSHAFT SPROCKET
Fig. 88 Measuring Idler Gear End Play
1 ± IDLER SPROCKET ASSEMBLY
2 ± DIAL INDICATOR
Fig. 89 Tapping Idler Shaft For Special Tool 8517
1 ± IDLER SHAFT
2 ± TAP 12mm X 1.75
DN4.7L ENGINE 9 - 55
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
NOTE: Position the right side camshaft so that the
camshaft sprocket dowel is near the 10 o'clock
position, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.
(2) Position the camshaft into the cylinder head.
(3) Install the camshaft bearing caps, hand tighten
the retaining bolts.
(4) Working in 1/2 turn increments, tighten the
bearing cap retaining bolts starting with the middle
cap working outward (Fig. 100).
(5) Torque the camshaft bearing cap retaining
bolts to 11 N´m (100 in. lbs.).
(6) Position the camshaft drive gear into the tim-
ing chain aligning the V8 mark between the two
marked chain links (Two links marked during
removal) (Fig. 101).
(7) Using the adjustable pliers, rotate the cam-
shaft until the camshaft sprocket dowel is aligned
with the slot in the camshaft sprocket. Install the
sprocket onto the camshaft (Fig. 102).
CAUTION: Remove excess oil from camshaft
sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.(8) Remove excess oil from camshaft sprocket bolt,
then install the camshaft sprocket retaining bolt and
hand tighten.
(9) Remove timing chain wedge special tool 8350
(Fig. 97).
(10) Using Special Tool 6958 spanner wrench with
adapter pins 8346 (Fig. 103), torque the camshaft
sprocket retaining bolt to 122 N´m (90 ft. lbs.).
(11) Install the camshaft position sensor (Fig. 98).
(12) Install the cylinder head cover.
CRANKSHAFT MAIN BEARINGS
CRANKSHAFT MAIN BEARING SELECTION
The main bearings are ªselect fitº to achieve proper
oil clearances. For main bearing selection, the crank-
shaft position sensor target wheel has grade identifi-
cation marks stamped into it (Fig. 104). These marks
are read from left to right, corresponding with jour-
nal number 1, 2, 3, 4 and 5. The crankshaft position
sensor target wheel is mounted to the number 8
counter weight on the crankshaft.
NOTE: Service main bearings color coded. These
color codes identify what size (grade) the bearing
is.
CHECKING CRANKSHAFT END PLAY
(1) Mount a dial indicator to a stationary point at
front of engine. Locate the probe perpendicular
against nose of crankshaft (Fig. 105).
(2) Move the crankshaft all the way to the rear of
it's travel.
(3) Zero the dial indicator.
(4) Move the crankshaft all the way to the front of
it's travel and read the dial indicator. Refer to Crank-
shaft End Play Specification Chart.
OIL PAN 4X2 VEHICLE
REMOVAL
(1) Drain the cooling system. Refer to COOLING
SYSTEM.
(2) Remove the upper fan shroud. Refer to proce-
dure in this section.
(3) Remove the throttle body resonator and air
inlet hose.
(4) Remove the intake manifold. Refer to proce-
dure in this section.
(5) Raise vehicle on hoist.
(6) Disconnect exhaust pipe at exhaust manifolds.
Refer to EXHAUST SYSTEM.
(7) Remove the structural dust cover (Fig. 106).
Refer to procedure in this section.
(8) Drain engine oil and remove oil filter.
(9) Position suitable jack under engine.
Fig. 100 Camshaft Bearing Caps Tightening
Sequence
DN4.7L ENGINE 9 - 61
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (5) Lower engine and install both the left and
right side engine mount through bolts (Fig. 107).
Tighten the nuts to 68 N´m (50 ft. lbs.).
(6) Remove jack and install oil filter.
(7) Install structural dust cover.
(8) Install exhaust pipe onto exhaust manifolds.
(9) Lower vehicle.
(10) Install intake manifold.
(11) Install throttle body resonator and air inlet
hose.
(12) Install upper fan shroud.
(13) Fill cooling system.
(14) Fill engine oil.(15) Start engine and check for leaks.
OIL PAN 4X4 VEHICLE
REMOVAL
NOTE: 4X4 vehicles equipped with a 4.7L engine
must have the front axle removed before the oil pan
can be removed.
(1) Remove the front axle from vehicle. Refer to
DIFFERENTIAL AND DRIVELINE.
(2) Remove the structural dust cover (Fig. 109).
Refer to procedure in this section.
(3) Drain the engine oil and remove oil filter.
NOTE: Do not pry on oil pan or oil pan gasket.
Gasket is mounted to engine and does not come
out with oil pan.
(4) Remove the oil pan mounting bolts and oil pan
(Fig. 110).
(5) Unbolt oil pump pickup tube and remove tube
and oil pan gasket from engine.
Fig. 107 Engine Mount Through Bolt and Nut
Removal / Installation
1 ± LOCKNUT AND WASHER
2 ± ENGINE MOUNT/INSULATOR
3 ± THROUGH BOLT
4 ± FRAME
Fig. 108 Oil Pan Mounting Bolts and Oil Pan
Fig. 109 Structural Dust Cover Removal /
Installation
Fig. 110 Oil Pan Mounting Bolts and Oil Pan
9 - 64 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (2) Remove accessory drive belt refer to Group 7,
Cooling System for procedure.
(3) Remove A/C compressor mouning fasteners and
set aside.(4) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(5) Remove upper radiator hose.
(6) Using Special Tools 6958 Spanner with Adapter
Pins 8346 loosen fan and viscous assembly from
water pump (Fig. 126).
(7) Remove fan and viscous assembly.
(8) Disconnect electrical connector for fan mounted
inside radiator shroud.
(9) Remove radiator shroud attaching fasteners.
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
(10) Remove radiator shroud.
(11) Remove crankshaft damper bolt.
(12) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 127).
(13) Using Special Tool 8511, remove crankshaft
front seal (Fig. 128).
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Using Special Tool 8348 and 8512, install
crankshaft front seal (Fig. 129).
Fig. 124 Oil Pump and Primary Timing Chain
Tightening Sequence
Fig. 125 Oil Pressure Sending Unit
1 ± BELT
2 ± OIL PRESSURE SENSOR
3 ± OIL FILTER
4 ± ELEC. CONNECTOR
Fig. 126 Fan AssemblyÐRemoval/Installation
1 ± SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2±FAN
DN4.7L ENGINE 9 - 71
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CAUTION: Special Tool 8512, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.(2) Assemble Special Tool 8512 as follows, The nut
is threaded onto the shaft first. Then the roller bear-
ing is placed onto the threaded rod (The hardened
bearing surface of the bearingMUSTface the nut).
Then the hardened washer slides onto the threaded
rod (Fig. 130). Once assembled coat the threaded
rod's threads with MopartNickel Anti-Seize or (Loc-
tite No. 771).
(3) Align crankshaft damper slot with key in
crankshaft. Slide damper onto crankshaft slightly.
(4) Using Special Tool 8512 press damper onto
crankshaft (Fig. 131).
(5) Install then tighten crankshaft damper bolt to
175 N´m (130 ft. lbs.).
(6) Install radiator shroud and tighten fasteners to
11 N´m (95 in. lbs.).
(7) Connect electrical connector for shroud fan.
(8) Install fan and viscous assembly.
(9) Using Special Tools 6958 Spanner with Adapter
Pins 8346 tighten fan and viscous assembly to water
pump (Fig. 126).
(10) Install upper radiator hose.
(11) Install A/C compressor and tighten fasteners
to 54 N´m (40 ft. lbs.).
(12) Install accessory drive belt refer to Group 7,
Cooling System for procedure.
(13) Refill cooling system. Refer to Group 7, Cool-
ing System for procedure.
(14) Connect negative cable to battery.
Fig. 127 Crankshaft DamperÐRemoval
1 ± SPECIAL TOOL 8513 INSERT
2 ± SPECIAL TOOL 1026
Fig. 128 Crankshaft Front SealÐRemoval
1 ± SPECIAL TOOL 8511
Fig. 129 Crankshaft Front SealÐInstallation
1 ± TIMING CHAIN COVER
2 ± SPECIAL TOOL 8348
3 ± SPECIAL TOOL 8512
9 - 72 4.7L ENGINEDN
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 ENGINE MOUNTÐREAR
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Support the transmission with a transmission
jack.
(4) Remove stud nuts holding the insulator to the
crossmember (Fig. 34).
(5) Raise rear of transmission SLIGHTLY.
(6) Remove bolts holding the insulator to the insu-
lator bracket (Fig. 34). Remove the insulator.
INSTALLATION
(1) If the insulator bracket was removed, install
the bracket to the transmission (Fig. 34). Tighten the
bolts to 28 N´m (250 in. lbs.) torque.
(2) Install the bolts holding insulator to insulator
bracket. Tighten the bolts to 28 N´m (250 in. lbs.)
torque.
(3) Lower rear of transmission while aligning the
insulator studs into the mounting support bracket.Install stud nuts and tighten to 28 N´m (250 in. lbs.)
torque.
(4) Remove the transmission jack.
(5) Lower the vehicle.
(6) Connect the negative cable to the battery.
ENGINE ASSEMBLY
REMOVAL
(1) Scribe hood hinge outlines on hood. Remove the
hood.
(2) Disconnect the battery negative cable.
(3) Drain cooling system (refer to Group 7, Cooling
System for the proper procedure).
(4) Remove the air cleaner.
(5) Disconnect the radiator and heater hoses.
Remove radiator (refer to Group 7, Cooling System
for the correct procedures).
(6) Set fan shroud aside.
(7) Disconnect the vacuum supply lines from the
intake manifold.
(8) Remove the distributor cap and wires.
Fig. 33 Engine Mount Insulator at Frame
1 ± NUT
2 ± ENGINE SUPPORT BRACKET
3 ± INSULATOR
4 ± NUT
5 ± THROUGH BOLT
6 ± FRAME
7 ± FRONT AXLE
Fig. 34 Rear Mount Insulator
1 ± AUTOMATIC TRANSMISSION
2 ± INSULATOR BRACKET
3 ± INSULATOR
4 ± CROSSMEMBER
9 - 102 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)