Crankcase DODGE DURANGO 1999 1.G Owner's Manual

Downloaded from www.Manualslib.com manuals search engine CONDITION POSSIBLE CAUSES CORRECTION
3. Worn or incorrectly gapped spark
plugs3. Replace or clean and re-gap spark plugs (Refer to
group 8D, Ignition System)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or
crossed5. Check for correct firing order or replace spark plug
cables. (Refer to Group 8D, Ignition System for
correct procedures.)
6. Faulty coil 6. Test and replace, if necessary (Refer to group 8D,
Ignition System)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket and vacuum hoses.
Replace if necessary
8. EGR valve leaking or stuck open 8. Test and replace, if necessary (Refer to group 25,
Emission Control Systems)
ENGINE MISSES
ON
ACCELERATION1. Worn or incorrectly gapped spark
plugs1. Replace spark plugs or clean and set gap. (Refer
to group 8D, Ignition System)
2. Spark plug cables defective or
crossed2. Replace or rewire secondary ignition cables. Refer
to Group 8D, Ignition System
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary (refer to group 8D,
Ignition System)
MECHANICAL DIAGNOSIS CHARTÐGASOLINE ENGINES
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES/
LIFTERS1. High or low oil level
in crankcase1. Check for correct oil level. Adjust oil level by draining or adding
as needed
2. Thin or diluted oil 2. Change oil (Refer to Engine Oil Service in this group)
3. Low oil pressure 3. Check engine oil level. If ok, Perform oil pressure test. Refer to
this group for engine oil pressure test/specifications
4. Dirt in tappets/lash
adjusters4. Clean/replace hydraulic tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms and replace worn arms as
needed
7. Worn tappets/lash
adjusters7. Install new hydraulic tappets/lash adjusters
8. Worn valve guides 8. Inspect all valve guides and replace as necessary
9. Excessive runout of
valve seats or valve
faces9. Grind valves and seats
DN5.9L ENGINE 9 - 143
DIAGNOSIS AND TESTING (Continued)

Downloaded from www.Manualslib.com manuals search engine (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. 12). 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 dualSAE 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
particular ambient temperature range and variation
(Fig. 13).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the right
front of the engine, left of the generator on 5.9L
engines (Fig. 14).
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
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.
Fig. 12 Engine Oil Container Standard Notations
Fig. 13 Temperature/Engine Oil Viscosity
Recommendation
9 - 150 5.9L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine (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 the Maintenance Schedule. This infor-
mation can be found in your owner's manual.
TO CHANGE ENGINE OIL
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.
Refer to Hoisting and Jacking Recommendations.
(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 and
gasket 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 to remove
it from the cylinder block oil filter boss (Fig. 15).
(4) When filter separates from adapter nipple, tip
gasket end upward to minimize oil spill. Remove fil-
ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface (Fig. 16) of oil and grime.
OIL FILTER INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 16) hand
tighten filter one full turn, do not over tighten.
(3) Add oil, verify crankcase oil level and start
engine. Inspect for oil leaks.
REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Fig. 14 Engine Oil Dipstick LocationÐ5.9L Engines
1 ± CYLINDER HEAD COVER
2 ± ENGINE OIL FILL-HOLE CAP
3 ± DIPSTICK
4 ± ENGINE OIL FILTER
5 ± FILTER BOSS
Fig. 15 Oil Filter RemovalÐTypical
1 ± ENGINE OIL FILTER
2 ± OIL FILTER WRENCH
DN5.9L ENGINE 9 - 151
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 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. 18). 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. 19).
(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.
Service valves with oversize stems are available as
shown below.
Slowly turn reamer by hand and clean guide thor-
oughly before installing new valve.Ream the valve
guides from standard to 0.381 mm (0.015 inch).
Fig. 18 Positioning Valve with Tool C-3973
1 ± VALVE
2 ± SPACER TOOL
Fig. 19 Measuring Valve Guide Wear
1 ± VALVE
2 ± SPECIAL TOOL C-3339
DN5.9L ENGINE 9 - 153
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine 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.
(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. 40). 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. 41).
(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. 42).
(7) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 43). 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. 40 Throttle Body Assembly
1 ± FUEL RAIL ASSEMBLY
2 ± FUEL RAIL MOUNTING BOLTS
3 ± FUEL RAIL CONNECTING HOSES
Fig. 41 Plenum Pan Bolt Tightening Sequence
DN5.9L ENGINE 9 - 163
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. 44).
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.
Fig. 42 Cross-Over Gaskets
1 ± FRONT CROSS-OVER GASKET
2 ± REAR CROSS-OVER GASKET
Fig. 43 Intake Manifold Flange Gasket Alignment
1 ± FLANGE GASKET
2 ± ALIGNMENT TABS
3 ± CYLINDER HEAD GASKET
Fig. 44 Intake Manifold Bolt Tightening SequenceÐ
5.9L Engine
9 - 164 5.9L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (2) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(3) Remove the air inlet hose.
(4) Remove cylinder head cover and gasket. The
gasket may be used again.
INSTALLATION
(1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(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.
49). 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.
Fig. 48 Cylinder Head Cover Gasket
1 ± CYLINDER HEAD COVER GASKET
Fig. 49 Rocker Arms
1 ± ROCKER ARMS
2 ± CYLINDER HEAD
9 - 166 5.9L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine 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.
(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.
50). 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.
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
Fig. 50 Cylinder Head Bolt Tightening Sequence
DN5.9L ENGINE 9 - 167
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
2WD
(1) Fabricate 4 alignment dowels from 5/16x11/2
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier instal-
lation and removal with a screwdriver (Fig. 68).
(2) Install the dowels in the cylinder block (Fig. 69).
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 N´m (215 in. lbs.)
torque.
(8) Install the drain plug. Tighten drain plug to 34
N´m (25 ft. lbs.) torque.
(9) Lower transmission onto crossmember.
(10) Install rear support cushion mounting bolts.
Tighten bolts 28 N´m (250 in. lbs.).
(11) Raise engine by way of oil pan with a wood
block placed between jack and oil pan.(12) Remove through bolts from frame brackets
and lower engine. Install mount insulator through
bolts and tighten to 95 N´m (70 ft. lbs.).
(13) Install starter.
(14) Install transmission torque converter inspec-
tion cover.
(15) Install engine to transmission braces.
(16) Install exhaust pipe.
(17) Lower vehicle.
(18) Position throttle valve cable into bracket, then
attach to throttle body (Fig. 67A).
(19) Connect the distributor cap.
(20) Install dipstick.
(21) Install fan shroud.
(22) Install air cleaner assembly.
(23) Connect the negative cable to the battery.
(24) Fill crankcase with oil to proper level.
4WD
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier instal-
lation and removal with a screwdriver (Fig. 68).
(2) Install the dowels in the cylinder block (Fig. 69).(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.
(7)
Remove the dowels. Install the remaining oil pan
bolts. Tighten these bolts to 24 N´m (215 in. lbs.) torque.
(8) Install the drain plug. Tighten drain plug to 34
N´m (25 ft. lbs.) torque.
(9) Install transmission inspection cover.
(10) Install engine mount support brackets and
insulators.
(11) Install front drive axle. Refer to DIFFEREN-
TIAL and DRIVELINE.
(12) Lower vehicle
(13) Connect the distributor cap.
(14) Install dipstick.
(15) Connect the negative cable to the battery.
(16) Fill crankcase with oil to proper level.
PISTON AND CONNECTING ROD ASSEMBLY
REMOVAL
(1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.
(4) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cylin-
der block. Be sure to keep tops of pistons covered
during this operation.
(5) Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and
connecting rod assemblies, rotate crankshaft to center
the connecting rod in the cylinder bore and at BDC.
Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mating rod.
Fig. 68 Fabrication of Alignment Dowels
1 ± 1 1/2º x 5/16º BOLT
2 ± DOWEL
3 ± SLOT
Fig. 69 Position of Dowels in Cylinder Block
1 ± DOWEL
2 ± DOWEL
3 ± DOWEL
4 ± DOWEL
DN5.9L ENGINE 9 - 175
REMOVAL AND INSTALLATION (Continued)
2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99 December, 1999