Intake Manifold DODGE DURANGO 1998 1.G Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Scrape or wire brush all gasket surfaces to remove
all loose material. Inspect stamped parts to ensure
gasket rails are flat. Flatten rails with a hammer on
a flat plate, if required. Gasket surfaces must be free
of oil and dirt. Make sure the old gasket material is
removed from blind attaching holes.
GASKET APPLICATION
Assembling parts using a form-in-place gasket
requires care.
Mopar Silicone Rubber Adhesive Sealant should be
applied in a continuous bead approximately 3 mm
(0.12 inch) in diameter. All mounting holes must be
circled. For corner sealing,a3or6mm(1/8 or 1/4
inch) drop is placed in the center of the gasket con-
tact area. Uncured sealant may be removed with a
shop towel. Components should be torqued in place
while the sealant is still wet to the touch (within 10
minutes). The use of a locating dowel is recom-
mended during assembly to prevent smearing the
material off location.
Mopar Gasket Maker should be applied sparingly
to one gasket surface. The sealant diameter should
be 1.00 mm (0.04 inch) or less. Be certain the mate-
rial surrounds each mounting hole. Excess material
can easily be wiped off. Components should be
torqued in place within 15 minutes. The use of a
locating dowel is recommended during assembly to
prevent smearing the material off location.
ENGINE PERFORMANCE
It is important that the vehicle is operating to its
optimum performance level to maintain fuel economy
and the lowest emission levels. If vehicle is not oper-
ating to these standards, refer to Engine Diagnosis
outlined in this section. The following procedures can
assist in achieving the proper engine diagnosis.
(1) Test cranking amperage draw. Refer to Electri-
cal Group 8B, Cold Cranking Test.
(2) Check intake manifold bolt torque.
(3) Perform cylinder compression test. Refer to
Cylinder Compression Pressure Test in the Engine
Diagnosis area of this section.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified in Electrical Group 8D.
Tighten to specifications.
(5) Test resistance of spark plug cables. Refer to
Electrical Group 8D, Spark Plug Cables.
(6) Inspect the primary wires. Test coil output volt-
age and primary resistance. Replace parts as neces-
sary. Refer to Electrical Group 8D, for specifications.
(7) Test fuel pump for pressure. Refer to Group 14,
Fuel System Specifications.
(8) The air filter elements should be replaced as
specified in Lubrication and Maintenance, Group 0.(9) Inspect crankcase ventilation system as out
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.
(10) Road test vehicle as a final test.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
In gasoline engines, use an engine oil that is API
Service Grade Certified (Fig. 11). Standard engine oil
identification notations have been adopted to aid in
the proper selection of engine oil. The identifying
notations are located on the label of engine oil plastic
bottles and the top of engine oil cans. MOPAR only
provides engine oil that conforms to this certification.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 10W-30 specifies a multiple
viscosity engine oil. These are specified with a dual
SAE viscosity grade which indicates the cold-to-hot
temperature viscosity range. When choosing an
engine oil, consider the range of temperatures the
vehicle will be operated in before the next oil change.
Select an engine oil that is best suited to your area's
Fig. 11 Engine Oil Container Standard Notations
9 - 92 5.2L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine (4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50É to 60É
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
HYDROSTATIC LOCK
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure
(refer to Group 14, Fuel System).
(2) Disconnect the battery negative cable.
(3) Inspect air cleaner, induction system and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the plugs from the
engine.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(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 TIMING
(1) Turn crankshaft until the No.6 exhaust valve is
closing and No.6 intake valve is opening.(2) Insert a 6.350 mm (1/4 inch) spacer between
rocker arm pad and stem tip of No.1 intake valve.
Allow spring load to bleed tappet down giving in
effect a solid tappet.
(3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as pos-
sible. Zero the indicator.
(4) Rotate the crankshaft clockwise (normal run-
ning direction) until the valve has lifted 0.863 mm
(0.034 inch). The timing of the crankshaft should
now read from 10É before top dead center to 2É after
top dead center. Remove spacer.
CAUTION: DO NOT turn crankshaft any further
clockwise as valve spring might bottom and result
in serious damage.
If reading is not within specified limits:
²Check sprocket index marks.
²Inspect timing chain for wear.
²Check accuracy of DC mark on timing indicator.
VALVE SERVICE
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped
and cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE INSPECTION
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
VALVE GUIDES
Measure valve stem guide clearance as follows:
(1) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 17). The special
sleeve places the valve at the correct height for
checking with a dial indicator.
Fig. 17 Positioning Valve with Tool C-3973
1 ± VALVE
2 ± SPACER TOOL
DN5.2L ENGINE 9 - 95
SERVICE PROCEDURES (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)

Downloaded from www.Manualslib.com manuals search engine (9) Disconnect the accelerator linkage.
(10) Remove throttle body.
(11) Perform the Fuel System Pressure release
procedure (refer to Group 14, fuel System).
(12) Disconnect the fuel supply line.
(13) Disconnect the starter wires.
(14) Disconnect the oil pressure sending unit wire.
(15) Discharge the air conditioning system, if
equipped (refer to Group 24, Heating and Air Condi-
tioning for service procedures).
(16) Disconnect the air conditioning hoses.
(17) Disconnect the power steering hoses, if
equipped.
(18) Remove starter motor (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(19) Remove the generator (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(20) Raise and support the vehicle on a hoist.
(21) Disconnect exhaust pipe at manifold.
(22) Refer to Group 21, Transmissions for trans-
mission removal.
CAUTION: DO NOT lift the engine by the intake
manifold.
(23) Install an engine lifting fixture.
(24) The engine and front driving axle (engine/ax-
le/transmission) are connected through insulators
and support brackets. Separate the engine as follows:
²LEFT SIDEÐRemove 2 bolts attaching
(engine/pinion nose/transmission) bracket to trans-
mission bell housing. Remove 2 bracket to pinion
nose adaptor bolts. Separate engine from insulator by
removing upper nut washer assembly and bolt from
engine support bracket.
²RIGHT SIDEÐRemove 2 bracket to axle (dis-
connect housing) bolts and a bracket to bell housing
bolt. Separate engine from insulator by removing
upper nut washer assembly and bolt from engine
support bracket.
(25) Lower the vehicle.
(26) Install engine assembly on engine repair
stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Install the engine front mounts.
(5) Refer to Group, 21 Transmissions for transmis-
sion installation
(6) Install the inspection plate.
(7) Remove transmission support.
(8) Install exhaust pipe to manifold.
(9) Lower the vehicle.
(10) Remove engine lifting fixture.(11) Install the generator (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(12) Install starter motor (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(13) Connect power steering hoses, if equipped.
(14) Connect air conditioning hoses.
(15) Evacuate and charge the air conditioning sys-
tem, if equipped (refer to Group 24, Heater and Air
Conditioning for service procedures).
(16) Using a new gasket, install throttle body.
Tighten the throttle body bolts to 23 N´m (200 in.
lbs.) torque.
(17) Connect the accelerator linkage.
(18) Connect the starter wires.
(19) Connect the oil pressure sending unit wire.
(20) Install the distributor cap and wiring.
(21) Connect the vacuum supply lines to the
intake manifold.
(22) Connect the fuel supply lines.
(23) Install the radiator (refer to Group 7, Cooling
System). Connect the radiator hoses and heater
hoses.
(24) Install fan shroud in position.
(25) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure).
(26) Install the air cleaner.
(27) Install the battery.
(28) Warm engine and adjust.
(29) Install hood and line up with the scribe
marks.
(30) Road test vehicle.
INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain the cooling system. Refer to COOLING
SYSTEM.
(3) Remove the A/C compressor. Refer to HEAT-
ING and AIR CONDITIONING.
(4) Remove the generator. Refer to CHARGING
SYSTEM.
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner assembly and air inlet
hose.
(7) Perform the fuel pressure release procedure.
Refer to FUEL SYSTEM.
(8) Disconnect the fuel supply line from the fuel
rail. Refer to FUEL SYSTEM.
(9) Disconnect the accelerator linkage and, if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the coolant temperature sending
unit wire.
DN5.2L ENGINE 9 - 103
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 35). Dis-
card the throttle body gasket.
INSTALLATION
(1) If the plenum pan was removed, position pan
gasket and pan.
(2) Install plenum pan retaining bolts. (Fig. 36).
(3) Tighten plenum pan mounting bolts as follows:
²Step 1. Tighten bolts to 5.4 N´m (24 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check all bolts are at 9.5 N´m (84 in.
lbs.)
(4) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N´m
(200 in. lbs.) torque.
(5) Apply a bead of Mopar Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
The sealant bead height should be slightly higher
than the cross-over gaskets, approximately 5 mm (0.2
in). An excessive amount of sealant is not required to
ensure a leak proof seal, and an excessive amount of
sealant may reduce the effectiveness of the flange
gasket.
(6) Install the front and rear cross-over gaskets
onto the engine (Fig. 37).
(7) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face ofthe block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 38). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(8) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. long studs
at the front and rear of the manifold will help to
align the intake manifold. After intake manifold is in
Fig. 35 Throttle Body Assembly
1 ± FUEL RAIL ASSEMBLY
2 ± FUEL RAIL MOUNTING BOLTS
3 ± FUEL RAIL CONNECTING HOSES
Fig. 36 Plenum Pan Bolt Tightening Sequence
Fig. 37 Cross-Over Gaskets
1 ± FRONT CROSS-OVER GASKET
2 ± REAR CROSS-OVER GASKET
9 - 104 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine place, inspect to make sure seals are in place.
Remove alignment studs if used.
(9) The following torque sequence duplicates the
expected results of the automated assembly system
(Fig. 39).²Step 1ÐTighten bolts 1 thru 4, in sequence, to 8
N´m (72 in. lbs.) torque. Tighten in alternating steps
1.4 N´m (12 in. lbs.) torque at a time.
²Step 2ÐTighten bolts 5 thru 12, in sequence, to
8 N´m (72 in. lbs.) torque.
²Step 3ÐCheck that all bolts are tightened to 8
N´m (72 in. lbs.) torque.
²Step 4ÐTighten all bolts, in sequence, to 16 N´m
(12 ft. lbs.) torque.
²Step 5ÐCheck that all bolts are tightened to 16
N´m (12 ft. lbs.) torque.
(10) Install closed crankcase ventilation and evap-
oration control systems.
(11) Install the coil wires.
(12) Connect the coolant temperature sending unit
wire.
(13) Connect the heater hoses and bypass hose.
(14) Install distributor cap and wires.
(15) Connect the accelerator linkage and, if so
equipped, the speed control and transmission kick-
down cables.
(16) Install the fuel supply line to the fuel rail.
(17) Install the accessory drive bracket and A/C
compressor.
(18) Install the generator and accessory drive belt.
Tighten generator mounting bolt to 41 N´m (30 ft.
lbs.) torque.
(19) Install the air cleaner assembly and air inlet
hose.
(20) Fill cooling system.
(21) Connect the battery negative cable.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the battery negative cable.
(2) Raise the vehicle.
(3) Remove the exhaust pipe to manifold nuts.
(4) Lower the vehicle.
(5) Remove three nuts, heat shield and washers
from the right side exhaust manifold, if necessary
(Fig. 40).
(6) Remove two nuts, heat shield and washers
from the left side exhaust manifold, if necessary (Fig.
41).
(7) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(8) Remove manifold from the cylinder head.
INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the exhaust manifold, install new studs.
(1) Position the exhaust manifolds on the two
studs located on the cylinder head. Install conical
washers and nuts on these studs (Fig. 42).
Fig. 38 Intake Manifold Flange Gasket Alignment
1 ± FLANGE GASKET
2 ± ALIGNMENT TABS
3 ± CYLINDER HEAD GASKET
Fig. 39 Intake Manifold Bolt Tightening SequenceÐ
5.9L Engine
DN5.2L ENGINE 9 - 105
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (2) Position the cylinder head cover onto the gas-
ket. Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4) Install the air inlet hose.
(5) Connect the negative cable to the battery.
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Remove cylinder head cover and gasket. Refer
to Cylinder Head Cover in this section for correct
procedure.
(2) Remove the rocker arm bolts and pivots (Fig.
44). Place them on a bench in the same order as
removed.
(3) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
(1) Rotate the crankshaft until the ªV8º mark lines
up with the TDC mark on the timing chain case
cover. This mark is located 147É ATDC from the No.1
firing position.
(2) Install the push rods in the same order as
removed.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 N´m (21 ft. lbs.) torque.
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(4) Install cylinder head cover.
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE
(1) Remove the air cleaner.
(2) Remove cylinder head covers and spark plugs.(3) Remove coil wire from distributor and secure to
good ground to prevent engine from starting.
(4) Using suitable socket and flex handle at crank-
shaft retaining bolt, turn engine so the No.1 piston is
at TDC on the compression stroke.
(5) Remove rocker arms.
(6) With air hose attached to an adapter installed
in No.1 spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.
(7) Using Valve Spring Compressor Tool
MD-998772A with adaptor 6716A, compress valve
spring and remove retainer valve locks and valve
spring.
(8) Install seals on the exhaust valve stem and
position down against valve guides.
(9) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as a guide. DO NOT force seal against top
of guide. When installing the valve retainer locks,
compress the spring only enough to install the locks.
(10) Follow the same procedure on the remaining 7
cylinders using the firing sequence 1-8-4-3-6-5-7-2.
Make sure piston in cylinder is at TDC on the valve
spring that is being removed.
(11) Remove adapter from the No.1 spark plug
hole and install spark plugs.
(12) Install rocker arms.
(13) Install covers and coil wire to distributor.
(14) Install air cleaner.
(15) Road test vehicle.
CYLINDER HEAD
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system Refer to COOLING SYS-
TEM.
(3) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(4) Remove closed crankcase ventilation system.
(5) Disconnect the evaporation control system.
(6) Remove the air cleaner assembly and air inlet
hose.
(7) Perform fuel system pressure release proce-
dure. Refer to FUEL SYSTEM.
(8) Disconnect the fuel supply line.
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect heat indicator sending unit wire.
(13) Disconnect heater hoses and bypass hose.
(14) Remove cylinder head covers and gaskets.
Fig. 44 Rocker Arms
1 ± ROCKER ARMS
2 ± CYLINDER HEAD
DN5.2L ENGINE 9 - 107
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (15) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(16) Remove exhaust manifolds.
(17) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(18) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(19) Remove spark plugs.
INSTALLATION
(1) Position the new cylinder head gaskets onto
the cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(3) Starting at top center, tighten all cylinder head
bolts, in sequence, to 68 N´m (50 ft. lbs.) torque (Fig.
45). Repeat procedure, tighten all cylinder head bolts
to 143 N´m (105 ft. lbs.) torque. Repeat procedure to
confirm that all bolts are at 143 N´m (105 ft. lbs.)
torque.
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(4) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N´m
(21 ft. lbs.) torque.
(5) Install the intake manifold and throttle body
assembly.
(6) Install exhaust manifolds. Tighten the bolts
and nuts to 34 N´m (25 ft. lbs.) torque.
(7) Adjust spark plugs to specifications. Refer to
IGNITION SYSTEM. Install the plugs and tighten to
41 N´m (30 ft. lbs.) torque.
(8) Install coil wires.
(9) Connect heat indicator sending unit wire.(10) Connect the heater hoses and bypass hose.
(11) Install distributor cap and wires.
(12) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(13) Install the fuel supply line.
(14) Install the generator and drive belt. Tighten
generator mounting bolt to 41 N´m (30 ft. lbs.)
torque.
(15) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(16) Place the cylinder head cover gaskets in posi-
tion and install cylinder head covers. Tighten the
bolts to 11 N´m (95 in. lbs.) torque.
(17) Install closed crankcase ventilation system.
(18) Connect the evaporation control system.
(19) Install the air cleaner assembly and air inlet
hose.
(20) Install the heat shields. Tighten the bolts to
41 N´m (30 ft. lbs.) torque.
(21) Fill cooling system.
(22) Connect the battery negative cable.
VALVES AND VALVE SPRINGS
REMOVAL
(1) Remove the cylinder head. Refer to Cylinder
Head in this section for correct procedure.
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A and adapter 6716A.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.
INSTALLATION
(1) Clean valves thoroughly. Discard burned,
warped and cracked valves.
(2) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(3) Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
(4) Coat valve stems with lubrication oil and insert
them in cylinder head.
(5) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(6) Install new seals on all valve guides. Install
valve springs and valve retainers.
(7) Compress valve springs with Valve Spring
Compressor Tool MD-998772A and adapter 6716A,
install locks and release tool. If valves and/or seats
are ground, measure the installed height of springs.
Make sure the measurement is taken from bottom ofFig. 45 Cylinder Head Bolt Tightening Sequence
9 - 108 5.2L 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 (4) Remove intake manifold. Refer to Intake Man-
ifold in this section for the correct procedure.
(5) Remove cylinder head covers.
(6) Remove timing case cover and timing chain.
(7) Remove rocker arms.
(8) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
(9) Remove distributor and lift out the oil pump
and distributor drive shaft.
(10) Remove camshaft thrust plate, note location of
oil tab (Fig. 54).
(11) Install a long bolt into front of camshaft to aid
in removal of the camshaft. Remove camshaft, being
careful not to damage cam bearings with the cam
lobes.
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2
inches) of its final position in cylinder block.
(2) Install Camshaft Gear Installer Tool C-3509
with tongue back of distributor drive gear (Fig. 55).
(3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block.Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in
thrust plate.Tighten bolts to 24 N´m (210 in. lbs.)
torque. Top edge of tab should be flat against thrust
plate in order to catch oil for chain lubrication.
(5) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(6) Place timing chain around both sprockets.
(7) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(8) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(9) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 56).
(10) Install the camshaft bolt/cup washer. Tighten
bolt to 68 N´m (50 ft. lbs.) torque.
(11) Measure camshaft end play. Refer to Specifica-
tions for proper clearance. If not within limits install
a new thrust plate.
(12) Each tappet reused must be installed in the
same position from which it was removed.When
camshaft is replaced, all of the tappets must be
replaced.
Fig. 53 Camshaft and Sprocket Assembly
1 ± THRUST PLATE
2 ± OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL
WITH CAMSHAFT
3 ± CAMSHAFT SPROCKET
Fig. 54 Timing Chain Oil Tab Installation
1 ± THRUST PLATE FRONT SIDE
2 ± CHAIN OIL TAB
3 ± THRUST PLATE REAR SIDE
Fig. 55 Camshaft Holding Tool C-3509 (Installed
Position)
1 ± SPECIAL TOOL C-3509
2 ± DRIVE GEAR
3 ± DISTRIBUTOR LOCK BOLT
9 - 112 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)