cylinder DODGE DURANGO 1999 1.G Owners Manual

Downloaded from www.Manualslib.com manuals search engine DISASSEMBLY AND ASSEMBLY
VALVE SERVICE
VALVE GUIDES
Measure valve stem guide clearance as follows:
(1) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 75). The special
sleeve places the valve at the correct height for
checking with a dial indicator.(2) Attach Dial Indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 76).
(3) Move valve to and from the indicator. The total
dial indicator reading should not exceed 0.432 mm
(0.017 inch). Ream the guides for valves with over-
size stems if dial indicator reading is excessive or if
the stems are scuffed or scored.
(4) Service valves with oversize stems are avail-
able as shown below.
(5) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve.Ream the
valve guides from standard to 0.381 mm (0.015
inch). Use a 2 step procedure so the valve
guides are reamed true in relation to the valve
seat:
²Step 1ÐReam to 0.0763 mm (0.003 inch).
²Step 2ÐReam to 0.381 mm (0.015 inch).
Fig. 74 Core Hole Plug Removal
1 ± CYLINDER BLOCK
2 ± REMOVE PLUG WITH PLIERS
3 ± STRIKE HERE WITH HAMMER
4 ± DRIFT PUNCH
5 ± CUP PLUG
Fig. 75 Positioning Valve with Tool C-3973
1 ± VALVE
2 ± SPACER TOOL
Fig. 76 Measuring Valve Guide Wear
1 ± VALVE
2 ± SPECIAL TOOL C-3339
REAMER SIZES CHART
REAMER O/S VALVE GUIDE SIZE
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 - 0.317 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) (0.328 - 0.329 in.)
DN5.2L ENGINE 9 - 121
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CYLINDER BLOCK
DISASSEMBLE
With Engine removed from vehicle:
(1) Remove the cylinder heads. refer to Cylinder
Head in this section for correct procedure.
(2) Remove the exhaust manifolds. Refer to
Exhaust Manifolds in this section.
(3) Remove the oil pan. Refer to Oil Pan in this
section.
(4) Remove the piston and connecting rod assem-
blies. Refer to Piston and Connecting Rod in this sec-
tion.
(5) Remove the crankshaft. Refer to Crankshaft in
this section.
(6) Remove the core plugs.
ASSEMBLE
(1) Install the core plugs.
(2) Install the crankshaft.
(3) Install the piston and connecting rods.
(4) Install the oil pan.
(5) Install the cylinder heads.
(6) Install the exhaust manifolds.
(7) Install the intake manifold.
(8) Install the engine into the vehicle.
CLEANING AND INSPECTION
CYLINDER HEAD COVER
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
CYLINDER HEAD ASSEMBLY
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness
exceeds 0.00075 mm/mm (0.00075 inch/inch) times
the span length in inches in any direction, either
replace head or lightly machine the head surface.
FOR EXAMPLE:A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 X 0.00075 (12 X 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept-
able.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
PISTON AND CONNECTING ROD ASSEMBLY
INSPECTION
Check the crankshaft connecting rod journal for
excessive wear, taper and scoring.
Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
Check the pistons for taper and elliptical shape
before they are fitted into the cylinder bore (Fig. 83).
OIL PAN
CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove.DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
engine.
Fig. 82 Oil Pump
1 ± INNER ROTOR AND SHAFT
2 ± BODY
3 ± DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 ± COTTER PIN
5 ± RETAINER CAP
6 ± SPRING
7 ± RELIEF VALVE
8 ± LARGE CHAMFERED EDGE
9 ± BOLT
10 ± COVER
11 ± OUTER ROTOR
9 - 124 5.2L ENGINEDN
DISASSEMBLY AND ASSEMBLY (Continued)

Downloaded from www.Manualslib.com manuals search engine If oil pressure was low and pump is within specifi-
cations, inspect for worn engine bearings or other
reasons for oil pressure loss.
CYLINDER BLOCK
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
²The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.²The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
²The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.
Refer to Standard Service Procedures in the begin-
ning of this Group for the proper honing of cylinder
bores.
INTAKE MANIFOLD
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
EXHAUST MANIFOLD
CLEANING
Clean mating surfaces on cylinder head and mani-
fold, wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks, Inspect mating sur-
faces of manifold for flatness with a straight edge.
Seal surfaces must be flat within 0.1 mm (0.004 inch)
overall.
Fig. 90 Proper Installation of Retainer Cap
1 ± RETAINER CAP
2 ± CHAMFER
3 ± COTTER KEY
DN5.2L ENGINE 9 - 127
CLEANING AND INSPECTION (Continued)

Downloaded from www.Manualslib.com manuals search engine SPECIFICATIONS
5.2L ENGINE SPECIFICATIONS
ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type 90É V-8 OHV
Bore and Stroke 99.3 x 84.0 mm
(3.91 x 3.31 in.)
Displacement 5.2L
(318 c.i.)
Compression Ratio 9.1:1
Firing Order 1±8±4±3±6±5±7±2
Lubrication Pressure FeedÐ
Full Flow Filtration
Cooling System Liquid CooledÐ
Forced Circulation
Cylinder Block Cast Iron
Crankshaft Nodular Iron
Cylinder Head Cast Iron
Combustion Chambers Wedge-High Swirl
Valve shrouding
Camshaft Nodular Cast Iron
Pistons Aluminum Alloy w/strut
Connecting Rods Forged Steel
Cylinder Compression 689.5 kPa
Pressure (Min.) (100 psi)
CAMSHAFT
Bearing Diameter
No. 1 50.800 ± 50.825 mm
(2.000 ± 2.001 in.)
No. 2 50.394 ± 50.419 mm
(1.984 ± 1.985 in.)
No. 3 50.013 ± 50.038 mm
(1.969 ± 1.970 in.)
No. 4 49.606 ± 49.632 mm
(1.953 ± 1.954 in.)
DESCRIPTION SPECIFICATION
No. 5 39.688 ± 39.713 mm
(1.5625 ± 1.5635 in.)
Bearing Journal Diameter
No. 1 50.749 ± 50.775 mm
(1.998 ± 1.999 in.)
No. 2 50.343 ± 50.368 mm
(1.982 ± 1.983 in.)
No. 3 49.962 ± 49.987 mm
(1.967 ± 1.968 in.)
No. 4 49.555 ± 49.581 mm
(1.951 ± 1.952 in.)
No. 5 39.637 ± 39.662 mm
(1.5605 ± 1.5615 in.)
Bearing to Journal
Clearance
Standard 0.0254 ± 0.0762 mm
(0.001 ± 0.003 in.)
Service Limit 0.127 mm
(0.005 in.)
End Play 0.051 ± 0.254 mm
(0.002 ± 0.010 in.)
CONNECTING RODS
Piston Pin bore Diameter 24.966 ± 24.978 mm
(0.9829 ± 0.9834 in.)
Side Clearance 0.152 ± 0.356 mm
(0.006 ± 0.014 in.)
CRANKSHAFT
Rod Journal
Diameter 53.950 ± 53.975 mm
(2.124 ± 2.125 in.)
Out of Round (Max.) 0.0254 mm
(0.001 in.)
Taper (Max.) 0.0254 mm
(0.001 in.)
Bearing Clearance 0.013 ± 0.056 mm
(0.0005 ± 0.0022 in.)
Service Limit 0.0762 mm
(0.003 in.)
9 - 128 5.2L ENGINEDN

Downloaded from www.Manualslib.com manuals search engine DESCRIPTION SPECIFICATION
Main Bearing Journal
Diameter 63.487 ± 63.513 mm
(2.4995 ± 2.5005 in.)
Out of Round (Max.) 0.127 mm
(0.001 in.)
Taper (Max.) 0.0254 mm
(0.001 in.)
Bearing Clearance
(#1 Journal) 0.013 ± 0.038 mm
(0.0005 ± 0.0015 in.)
(#2-5 Journals) 0.013 ± 0.051 mm
(0.0005 ± 0.002 in.)
Service Limit
(#1 Journal) 0.0381 mm
(0.0015 in.)
(#2-5 Journals) 0.064 mm
(0.0025 in.)
End Play 0.051 ± 0.178 mm
(0.002 ± 0.007 in.)
Service Limit 0.254 mm
(0.010 in.)
CYLINDER BLOCK
Cylinder Bore
Diameter 99.308 ± 99.371 mm
(3.9098 ± 3.9122 in.)
Out of Round (Max.) 0.025 mm
(0.001 in.)
Taper (Max.) 0.025 mm
(0.001 in.)
Oversize Limit 1.016 mm
(0.040 in.)
Lifter Bore Diameter 22.99 ± 23.01 mm
(0.9051 ± 0.9059 in.)
Distributor Drive Bushing
(Press Fit)
Bushing to Bore
Interference0.0127 ± 0.3556 mm
(0.0005 ± 0.0140 in.)
Shaft to Bushing
Clearance0.0178 ± 0.0686 mm
(0.0007 ± 0.0027 in.)DESCRIPTION SPECIFICATION
CYLINDER HEAD
Valve Seat
Angle 44.25É ± 44.75É
Runout (Max.) 0.0762 mm
(0.003 in.)
Width (Finish)
Intake 1.016 ± 1.524 mm
(0.040 ± 0.060 in.)
Exhaust 1.524 ± 2.032 mm
(0.060 ± 0.080 in.)
VA LV E S
Face Angle 43.25É ± 43.75É
Head Diameter
Intake 48.666 mm
(1.916 in.)
Exhaust 41.250 mm
(1.624 in.)
Length (Overall)
Intake 124.28 ± 125.92 mm
(4.893 ± 4.918 in.)
Exhaust 124.64 ± 125.27 mm
(4.907 ± 4.932 in.)
Lift (@ zero lash) 10.973 mm
(0.432 in.)
Stem Diameter 7.899 ± 7.925 mm
(0.311 ± 0.312 in.)
Guide Bore 7.950 ± 7.976 mm
(0.313 ± 0.314 in.)
Stem to Guide Clearance 0.0254 ± 0.0762 mm
(0.001 ± 0.003 in.)
Service Limit (rocking
method)0.4318 mm
(0.017 in.)
DN5.2L ENGINE 9 - 129
SPECIFICATIONS (Continued)

Downloaded from www.Manualslib.com manuals search engine DESCRIPTION SPECIFICATION
PISTON PIN
Clearance in Piston 0.00635 ± 0.01905 mm
(0.00025 ± 0.00075 in.)
Diameter 24.996 ± 25.001 mm
(0.9841 ± 0.9843 in.)
End Play NONE
Length 75.946 ± 76.454 mm
(2.990 ± 3.010 in.)
PISTON RINGS
Ring Gap
Compression Rings 0.254 ± 0.508 mm
(0.010 ± 0.020 in.)
Oil Control (Steel Rails) 0.254 ± 1.270 mm
(0.010 ± 0.050 in.)
Ring Side Clearance
Compression Rings 0.038 ± 0.076 mm
(0.0015 ± 0.0030 in.)
Oil Ring (Steel Rails) 0.06 ± 0.21 mm
(0.002 ± 0.008 in.)
Ring Width
Compression rings 1.971 ± 1.989 mm
(0.0776 ± 0.0783 in.)
Oil Ring (Steel Rails) ±
Max.3.848 ± 3.975 mm
(0.1515 ± 0.1565 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) 21É
Opens (BBDC) 60É
Duration 264É
Intake Valve
Closes (ATDC) 61É
Opens (BBDC) 10É
Duration 250É
Valve Overlap 31ÉOVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
U/S-O/S Item Identification Identification
Location
U/S Rod/ R or M R-1-4
ect.Milled flat on
No.8
.0254
mmMain (indicating
No. 1crankshaft
(0.001
in.)Journal and 4
connectingcounterweight.
rod journal)
and/or
M-2-3 ect.
(indicating
No. 2
and 3 main
bearing
journal)
O/S HydrauliclDiamond-
shaped
.2032
mmTappets stamp top pad
-
(.008 in.) front of engine
and flat
ground
on outside
surface of
each
O/S tappet
bore.
O/S Valve X Milled pad
.127 mm Stems adjacent to
two
(.005 in.) tapped holes
(3/8 in.) on
each
end of
cylinder
head.
DN5.2L ENGINE 9 - 131
SPECIFICATIONS (Continued)

Downloaded from www.Manualslib.com manuals search engine TORQUE SPECIFICATIONS
TORQUE CHART 5.2L ENGINE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 50 Ð
Camshaft Thrust PlateÐBolts 24 Ð 210
Chain Case CoverÐBolts 41 30 Ð
Connecting Rod CapÐBolts 61 45 Ð
Main Bearing CapÐBolts 115 85 Ð
Crankshaft PulleyÐBolts 24 Ð 210
Cylinder HeadÐBolts
Step 1 68 50 Ð
Step 2 143 105 Ð
Cylinder Head CoverÐBolts 11 Ð 95
Engine Support Bracket to
BlockÐ41 30 Ð
Bolts (4WD)
Exhaust Manifold to Cylinder
HeadÐ34 25 Ð
Bolts/Nuts
FlywheelÐBolts 75 55 Ð
Front InsulatorÐThrough
bolt/nut95 70 Ð
Front Insulator to Support
BracketÐ
Stud Nut (4WD) 41 30 Ð
Through Bolt/Nut 102 75 Ð
Front Insulator to BlockÐ 95 70 Ð
Bolts (2WD)
GeneratorÐMounting Bolts 41 30 Ð
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 Ð 215
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐMounting Bolts 41 30 Ð
Oil Pump CoverÐBolts 11 Ð 95
Rear Insulator to BracketÐ
Through68 50 Ð
Bolt (2WD)
Rear Insulator to
Crossmember41 30 Ð
Support BracketÐNut (2WD)
Rear Insulator to
CrossmemberÐ68 50 Ð
Nuts (4WD)
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Rear Insulator to
TransmissionÐ68 50 Ð
Bolts (4WD)
Rear Insulator BracketÐBolts 68 50 Ð
(4WD Automatic)
Rear Support Plate to
Transfer Case41 30 Ð
ÐBolts
Rocker ArmÐBolts 28 21 Ð
Spark Plugs 41 30 Ð
Starter MotorÐMounting
Bolts68 50 Ð
Thermostat HousingÐBolts 25 Ð 225
Throttle BodyÐBolts 23 Ð 200
Torque Converter Drive
PlateÐBolts31 Ð 270
Transfer Case to Insulator
Mounting204 150 Ð
PlateÐNuts
Transmission Support
BracketÐ68 50 Ð
Bolts (2WD)
Vibration DamperÐBolt 183 135 Ð
Water Pump to Timing Chain
Case41 30 Ð
CoverÐBolts
SPECIAL TOOLS
5.2L ENGINE
Oil Pressure Gauge C-3292
9 - 132 5.2L ENGINEDN
SPECIFICATIONS (Continued)

Downloaded from www.Manualslib.com manuals search engine Distributor Bushing Puller C-3052
Distributor Bushing Driver/Burnisher C-3053
Piston Ring Compressor C-385
Crankshaft Main Bearing Remover C-3059
Cylinder Bore Gauge C-119
9 - 134 5.2L ENGINEDN
SPECIAL TOOLS (Continued)

Downloaded from www.Manualslib.com manuals search engine 5.9L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ENGINE...............................136
ENGINE LUBRICATION SYSTEM............136
EXHAUST MANIFOLD....................139
INTAKE MANIFOLD......................139
CYLINDER HEAD COVER GASKET..........140
CYLINDER HEAD........................140
VALVES AND VALVE SPRINGS.............140
ENGINE OIL PAN........................140
CRANKSHAFT OIL SEALS.................140
PISTON AND CONNECTING ROD...........140
CRANKSHAFT MAIN BEARINGS............141
CRANKSHAFT..........................141
DIAGNOSIS AND TESTING
ENGINE DIAGNOSISÐINTRODUCTION.......141
SERVICE DIAGNOSISÐGASOLINE ENGINES . . 142
INTAKE MANIFOLD LEAKAGE DIAGNOSIS....145
CYLINDER COMPRESSION PRESSURE TEST . 145
CYLINDER HEAD GASKET FAILURE
DIAGNOSIS...........................146
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST.......................146
INSPECTION (ENGINE OIL LEAKS IN
GENERAL)...........................147
REAR SEAL AREA LEAKSÐINSPECTION.....147
HYDRAULIC TAPPETS....................148
ENGINE OIL PRESSURE..................148
SERVICE PROCEDURES
FORM-IN-PLACE GASKETS................149
ENGINE PERFORMANCE.................149
ENGINE OIL............................150
REPAIR DAMAGED OR WORN THREADS.....151
CYLINDER BOREÐHONING...............152
HYDROSTATIC LOCK.....................152
VALVE TIMING..........................153
VALVE SERVICE........................153
MEASURING TIMING CHAIN STRETCH.......155
PISTONSÐFITTING......................156
PISTON RINGSÐFITTING.................156
CONNECTING ROD BEARINGSÐFITTING.....157
CRANKSHAFT MAIN BEARINGSÐFITTING....157
REMOVAL AND INSTALLATION
ENGINE FRONT MOUNTS.................158ENGINE REAR SUPPORT.................160
ENGINE ASSEMBLY......................161
INTAKE MANIFOLD......................163
EXHAUST MANIFOLD....................165
CYLINDER HEAD COVER.................165
ROCKER ARMS AND PUSH RODS..........166
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE.............166
CYLINDER HEAD........................167
VALVES AND VALVE SPRINGS.............167
HYDRAULIC TAPPETS....................168
VIBRATION DAMPER.....................168
TIMING CHAIN COVER...................169
TIMING CHAIN..........................170
CAMSHAFT............................170
CAMSHAFT BEARINGS...................172
DISTRIBUTOR DRIVE SHAFT BUSHING......172
CRANKSHAFT MAIN BEARINGS............174
OILPAN...............................174
PISTON AND CONNECTING ROD ASSEMBLY . . 175
CRANKSHAFT..........................176
OIL PUMP.............................177
CRANKSHAFT OIL SEALÐFRONT...........178
CRANKSHAFT OIL SEALSÐREAR...........179
ENGINE CORE OIL AND CAMSHAFT PLUGS . . 180
DISASSEMBLY AND ASSEMBLY
OIL PUMP.............................181
CLEANING AND INSPECTION
CYLINDER HEAD COVER.................182
CYLINDER HEAD ASSEMBLY..............182
PISTON AND CONNECTING ROD ASSEMBLY . . 182
OILPAN...............................182
OIL PUMP.............................182
CYLINDER BLOCK.......................185
INTAKE MANIFOLD......................185
EXHAUST MANIFOLD....................185
SPECIFICATIONS
5.9L ENGINE SPECIFICATIONS.............185
SPECIFICATIONS........................189
SPECIAL TOOLS
5.9L ENGINE...........................189
DN5.9L ENGINE 9 - 135

Downloaded from www.Manualslib.com manuals search engine DESCRIPTION AND OPERATION
ENGINE
DESCRIPTION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
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).
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).
ENGINE LUBRICATION SYSTEM
DESCRIPTION
A gear-type positive displacement pump (Fig. 3) is
mounted at the underside of the rear main bearing
cap. The pump uses a pick-up tube and screen
assembly to gather engine oil from the oil pan.
OPERATION
The pump draws oil through the screen and inlet
tube from the sump at the rear of the oil pan. The oil
is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery that
channels the oil up to the main gallery, which
extends the entire length on the right side of the
block. The oil then goes down to the No. 1 main bear-
ing, back up to the left side of the block, and into the
oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod
rotates. This oil throwoff lubricates the camshaft
lobes, distributor drive gear, cylinder walls, and pis-
ton pins.
Fig. 1 Firing Order
Fig. 2 Engine Identification Number
Fig. 3 Positive Displacement Oil PumpÐTypical
1 ± INNER ROTOR AND SHAFT
2 ± BODY
3 ± DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 ± COTTER PIN
5 ± RETAINER CAP
6 ± SPRING
7 ± RELIEF VALVE
8 ± LARGE CHAMFERED EDGE
9 ± BOLT
10 ± COVER
11 ± OUTER ROTOR
9 - 136 5.9L ENGINEDN