Exhaust DODGE DURANGO 1999 1.G Owner's Manual
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Page 46 of 193

Downloaded from www.Manualslib.com manuals search engine (14) Install the crankshaft damper. Tighten
damper bolt 175 N´m (130 Ft. Lbs.).
(15) Install accessory drive belt.
(16) Install the fan shroud.
(17) Install the cylinder head cover.
(18) Install the intake manifold.
(19) Install oil fill housing onto cylinder head.
(20) Refill the cooling system.
(21) Raise the vehicle.
(22) Install the exhaust pipe onto the right
exhaust manifold.
(23) Lower the vehicle.
(24) Reconnect battery negitive cable.
(25) Start the engine and check for leaks.
VALVE SPRINGS AND SEALS
REMOVAL
(1) Remove the cylinder head cover. Refer to Cyl-
inder Head Cover in this Section.
(2) Using Special Tool 8516 Valve Spring Compres-
sor, remove the rocker arms and the hydraulic lash
adjusters (Fig. 67).
(3) Remove the spark plug for the cylinder the
valve spring and seal are to be removed from.
(4) Apply shop air to the cylinder to hold the
valves in place when the spring is removed
(5) Remove the camshaft. Refer to Camshaft in
this section.NOTE: All eight valve springs and seals are
removed in the same manner; this procedure only
covers one valve seal and valve spring.
(6) Using Special Tool 8387 Valve Spring Compres-
sor, compress the valve spring.
NOTE: It may be necessary to tap the top of the
valve spring to loosen the spring retainers locks
enough to be removed.
(7) Remove the two spring retainer lock halves.
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
(8) Remove the valve spring compressor.
(9) Remove the spring retainer, and the spring.
(10) Remove the valve stem seal.
NOTE: The valve stem seals are common between
intake and exhaust.
INSTALLATION
(1) coat the valve stem with clean engine oil and
install the valve stem seal. make sure the seal is
fully seated and that the garter spring at the top of
the seal is intact.
(2) Install the spring and the spring retainer.
(3) Using Special Tool 8387 Valve Spring Compres-
sor, compress the spring and install the two valve
spring retainer halves.
(4) Release the valve spring compressor and make
sure the two spring retainer halves and the spring
retainer are fully seated.
(5) Install the camshaft. Refer to Camshaft in this
section.
(6) Position the hydraulic lash adjusters and
rocker arms (Fig. 67).
(7) Install the cylinder head cover.
HYDRAULIC LASH ADJUSTER
REMOVAL
(1) Remove cylinder head cover(s). Refer to proce-
dure in this section.
(2) Remove rocker arm(s). Refer to procedure in
this section.
CAUTION: If lash adjusters and rocker arms are to
be reused, always mark position for reassembly in
their original positions.
(3) Remove lash adjuster(s).
Fig. 67 Rocker ArmÐRemoval
1 ± CAMSHAFT
2 ± SPECIAL TOOL 8516
9 - 46 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)
Page 47 of 193

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)
Page 49 of 193

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)
Page 61 of 193

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)
Page 64 of 193

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)
Page 75 of 193

Downloaded from www.Manualslib.com manuals search engine NOTE: Once the oil pressure relief valve, cup plug,
and pin are removed, the pump assembly must be
replaced.
(3) If it is necessary to remove the pressure relief
valve, drive the roll pin from pump housing and
remove cup plug, spring and valve.
ASSEMBLE
(1) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
(2) Install inner and outer rotors
(3) Install oil pump cover plate and install cover
bolts and tighten them to 12 N´m (105 in. lbs.).
(4) Prime oil pump before installation by filling
rotor cavity with engine oil.
(5) If oil pressure is low and pump is within spec-
ifications, inspect for worn engine bearings or other
causes for oil pressure loss.
CLEANING AND INSPECTION
INTAKE MANIFOLD
CLEANING
NOTE: There is NO approved repair procedure for
the intake manifold. If severe damage is found dur-
ing inspection, the intake manifold must be
replaced.
Before installing the intake manifold thoroughly
clean the mating surfaces. Use a suitable cleaning
solvent, then air dry.
INSPECTION
(1) Inspect the intake sealing surface for cracks,
nicks and distortion.
(2) Inspect the intake manifold vacuum hose fit-
tings for looseness or blockage.
(3) Inspect the manifold to throttle body mating
surface for cracks, nicks and distortion.
EXHAUST MANIFOLD
CLEANING
(1) Clean the exhaust manifold using a suitable
cleaning solvent, then allow to air dry.
(2) Clean all gasket residue from the manifold
mating surface.
INSPECTION
(1) Inspect the exhaust manifold for cracks in the
mating surface and at every mounting bolt hole.
(2) Using a straight edge and a feeler gauge, check
the mating surface for warp and twist.(3) Inspect the manifold to exhaust pipe mating
surface for cracks, gouges, or other damage that
would prevent sealing.
CYLINDER HEADS
CLEANING
CYLINDER HEAD GASKET SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components.
Never use the following to clean gasket surfaces:
²never use a metal scraper.
²never use an abrasive pad or paper to
clean the cylinder block.
²never use a high speed power tool or wire
brush on any gasket sealing surface(Fig. 136).
Only use the following for cleaning gasket surfaces:
²use MopartBrake and Parts Cleaner
²use only a plastic or wood scraper (Fig. 136)
INSPECTION
(1) Inspect the cylinder head for out-of-flatness,
using a straightedge and a feeler gauge. If tolerances
exceed 0.0508 mm (0.002 in.) replace the cylinder
head.
(2) Inspect the valve seats for damage. Service the
valve seats as necessary.
(3) Inspect the valve guides for wear, cracks or
looseness. If either condition exist, replace the cylin-
der head.
Fig. 136 Proper Tool Usage For Surface Preparation
1 ± PLASTIC/WOOD SCRAPER
DN4.7L ENGINE 9 - 75
DISASSEMBLY AND ASSEMBLY (Continued)
Page 80 of 193

Downloaded from www.Manualslib.com manuals search engine DESCRIPTION SPECIFICATION
Exhaust
Opens (BTDC) 232.5É
Closes (ATDC) 21.2É
Duration 253.70É
Valve Overlap 17.6É
VA LV E S
Face Angle 45É - 45.5É
Head Diameter
Intake 48.52 - 48.78 mm
(1.9103 - 1.9205 in.)
Exhaust 36.87 - 37.13 mm
1.4516 - 1.4618 in.)
Length (Overall)
Intake 113.45 - 114.21 mm
(4.4666 - 4.4965)
Exhaust 114.92 - 115.68 mm
(4.5244 - 4.5543 in.)
Stem Diameter
Intake 6.931 - 6.957 mm
(0.2729 - 0.2739 in.)
Exhaust 6.902 - 6.928 mm
(0.2717 - 0.2728 in.)
Stem - to - Guide
Clearance
Intake .018 -.069 mm
(0.0008 - 0.0028 in.)
Exhaust .047 -.098 mm
(0.0019 - 0.0039 in.)
Max. Allowable Stem -
to -
Guide Clearance
(Rocking Method)
Intake 0.069 mm (0.0028 in.)
Exhaust 0.098 mm (0.0039 in.)
Valve Lift (Zero Lash)
Intake 11.25 mm (0.443 in.)
Exhaust 10.90 mm (0.4292 in.)
VALVE SPRING
Free Lenght (Approx)
Intake and Exhaust 48.6 mm (1.9134 in.)DESCRIPTION SPECIFICATION
Spring Force (Valve
Closed)
Intake and Exhaust 315.5 - 352.5 N @ 40.89
mm
(70.92722 - 79.24515 lbs.
@ 1.6099 in.)
Spring Force (Valve
Open)
Intake and Exhaust 786.0 - 860.0 N @ 29.64
mm
176.6998 - 193.3357 lbs.
@ 1.167 in.)
Number of Coils
Intake and Exhaust 6.69
Wire Diameter
Intake and Exhaust 4.2799 - 4.3561 mm
(0.1685 - 0.1715 in.)
Installed Height
(Top of Valve Stem Seal
to Bottom of Retainer)
Nominal
Early Build
Intake 40.97 mm (1.613 in.)
Exhaust 40.81 mm (1.606 in.)
Late Build
Intake 40.11 mm (1.5792 in.)
Exhaust 40.13 mm (1.58 in.)
CYLINDER HEAD
Gasket Thickness
(Compressed) .7 mm (0.0276 in.)
Valve Seat Angle 44.5É - 45.0É
Valve Seat Runout (MAX) 0.051 mm (0.002 in.)
Valve Seat Width
Intake 1.75 - 2.36 mm
(0.0698 - 0.0928 in.)
Exhaust 1.71 - 2.32 mm
(0.0673 - 0.0911 in.)
Guide Bore Diameter (Std.)6.975 - 7.00 mm
(0.2747 - 0.2756 in.)
Cylinder Head Warpage
(Flatness) 0.0508 mm (0.002 in.)
9 - 80 4.7L ENGINEDN
SPECIFICATIONS (Continued)
2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99 December, 1999
Page 81 of 193

Downloaded from www.Manualslib.com manuals search engine DESCRIPTION SPECIFICATION
OIL PUMP
Clearance Over Rotors
(MAX).035 -.095 mm
(0.0014 - 0.0038 in.)
Cover Out - of -Flat
(MAX).025 mm (0.001 in.)
Inner and Outer Rotor
Thickness 12.08 mm (0.4756 in.)
Outer Rotor Clearance
(MAX)85.96 mm (3.3843 in.)
Outer Rotor Diameter
(MIN)85.925 mm (0.400 in.)
Tip Clearance Between
Rotors
(MAX) .150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed
(MIN)*25 kPa (4 psi)
@ 3000 rpm 170 - 550 kPa (25 - 80
psi)
* CAUTION: If pressure is zero at curb idle, DO
NOT run engine at 3000 rpm.
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90 Ð
Bearing Cap Bolts 11 Ð 100
Timing Chain CoverÐBolts 54 40 Ð
Connecting Rod CapÐBolts 27 20 Ð
PLUS 90É TURN
Bed PlateÐBolts Refer to Procedure
Crankshaft DamperÐBolt 175 130 Ð
Cylinder HeadÐBolts
M11 Bolts 81 60 Ð
M8 Bolts 28 Ð 250
Cylinder Head CoverÐBolts 12 Ð 105
Exhaust ManifoldÐBolts 25 18 Ð
Exhaust Manifold Heat
ShieldÐNuts8Ð72
Then loosen 45É
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
FlexplateÐBolts 60 45 Ð
Engine Mount Bracket to
BlockÐBolts61 45 Ð
Rear Mount to
TransmissionÐBolts46 34 Ð
Generator MountingÐBolts
M10 Bolts 54 40 Ð
M8 Bolts 28 Ð 250
Intake ManifoldÐBolts 12 Ð 105
Refer to Procedure
for
Tightening Sequence
Oil PanÐBolts 15 Ð 130
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐBolts 28 Ð 250
Oil Pump CoverÐBolts 12 Ð 105
Oil Pickup TubeÐBolt and
Nut28 Ð 250
Oil Dipstick TubeÐBolt 28 Ð 250
Oil Fill TubeÐBolts 12 Ð 105
Timing Chain GuideÐBolts 28 Ð 250
Timing Chain Tensioner
ArmÐSpecial
Pin Bolt 17 Ð 150
Hydraulic TensionerÐBolts 28 Ð 250
Timing Chain Primary
TensionerÐBolts28 Ð 250
Timing Drive Idler SprocketÐ
Bolt34 25 Ð
Thermostat HousingÐBolts 12 Ð 105
Water PumpÐBolts 54 40 Ð
DN4.7L ENGINE 9 - 81
SPECIFICATIONS (Continued)
Page 86 of 193

Downloaded from www.Manualslib.com manuals search engine 5.2L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ENGINE................................86
ENGINE LUBRICATION SYSTEM.............87
EXHAUST MANIFOLD.....................89
INTAKE MANIFOLD.......................89
CYLINDER HEAD COVER GASKET...........90
CYLINDER HEAD.........................90
VALVES AND VALVE SPRINGS..............90
ENGINE OIL PAN.........................90
CRANKSHAFT OIL SEALS..................90
PISTON AND CONNECTING ROD............90
CRANKSHAFT MAIN BEARINGS.............91
CRANKSHAFT...........................91
SERVICE PROCEDURES
FORM-IN-PLACE GASKETS.................91
ENGINE PERFORMANCE..................92
ENGINE OIL.............................92
REPAIR DAMAGED OR WORN THREADS......94
CYLINDER BOREÐHONING................94
HYDROSTATIC LOCK.....................95
VALVE TIMING...........................95
VALVE SERVICE.........................95
MEASURING TIMING CHAIN STRETCH........97
PISTONSÐFITTING.......................98
PISTON RINGSÐFITTING..................98
CONNECTING ROD BEARINGSÐFITTING.....100
CRANKSHAFT MAIN BEARINGSÐFITTING....100
REMOVAL AND INSTALLATION
ENGINE MOUNTSÐFRONT................100
ENGINE MOUNTÐREAR..................102
ENGINE ASSEMBLY......................102
INTAKE MANIFOLD......................103
EXHAUST MANIFOLD....................105
CYLINDER HEAD COVER.................106
ROCKER ARMS AND PUSH RODS..........107
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE.............107CYLINDER HEAD........................107
VALVES AND VALVE SPRINGS.............108
HYDRAULIC TAPPETS....................109
VIBRATION DAMPER.....................109
TIMING CHAIN COVER...................110
TIMING CHAIN..........................111
CAMSHAFT............................111
CAMSHAFT BEARINGS...................113
CRANKSHAFT MAIN BEARINGS............113
DISTRIBUTOR DRIVE SHAFT BUSHING......114
OILPAN...............................115
PISTON AND CONNECTING ROD ASSEMBLY . . 116
CRANKSHAFT..........................116
OIL PUMP.............................117
CRANKSHAFT OIL SEALÐFRONT...........117
CRANKSHAFT OIL SEALSÐREAR...........118
ENGINE CORE OIL AND CAMSHAFT PLUGS . . 120
DISASSEMBLY AND ASSEMBLY
VALVE SERVICE........................121
OIL PUMP.............................123
CYLINDER BLOCK.......................124
CLEANING AND INSPECTION
CYLINDER HEAD COVER.................124
CYLINDER HEAD ASSEMBLY..............124
PISTON AND CONNECTING ROD ASSEMBLY . . 124
OILPAN...............................124
OIL PUMP.............................125
CYLINDER BLOCK.......................127
INTAKE MANIFOLD......................127
EXHAUST MANIFOLD....................127
SPECIFICATIONS
5.2L ENGINE SPECIFICATIONS.............128
TORQUE SPECIFICATIONS................132
SPECIAL TOOLS
5.2L ENGINE...........................132
DESCRIPTION AND OPERATION
ENGINE
DESCRIPTION
The 5.2 Liter (318 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets.
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). This
engine is designed for unleaded fuel.
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).
9 - 86 5.2L ENGINEDN
Page 89 of 193

Downloaded from www.Manualslib.com manuals search engine EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds are constructed of cast iron
and are LOG type with balanced flow (Fig. 5). One
exhaust manifold is attached to each cylinder head.
OPERATION
The exhaust manifolds collect the engine exhaust
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipes attached to the
manifolds.
INTAKE MANIFOLD
DESCRIPTION
The aluminum intake manifold (Fig. 6) is a single
plane design with equal length runners and uses a
separate plenum, therefore the manifold does have a
plenum gasket. It also uses separate flange gaskets
and front and rear cross-over gaskets. Extreme caremust be used when sealing the gaskets to ensure
that excess sealant does not enter the intake runners
causing a restriction. Whenever the intake manifold
is removed inspect the plenum pan for evidence of
excess oil buildup, this condition indicates that the
plenum pan gasket is leaking.
OPERATION
The intake manifold, meters and delivers air to the
combustion chambers allowing the fuel delivered by
the fuel injectors to ignite, thus producing power.
1 ± OIL DEFLECTOR TAB
2 ± BOLT
3 ± ROCKER ARM PIVOT
4 ± ROCKER ARM
5 ± DRIP OILING FOR VALVE TIP
6 ± CYLINDER HEAD BOSS
7 ± TO MAIN BEARINGS
8 ± TO CAMSHAFT BEARINGS
9 ± ROCKER ARM
10 ± HOLLOW PUSH ROD
11 ± TAPPET
12 ± TO CONNECTING ROD BEARINGS
13 ± OIL INTAKE14 ± OIL PUMP
15 ± OIL FILTER
16 ± CRANKSHAFT
17 ± FROM OIL PUMP
18 ± OIL TO FILTER
19 ± OIL FROM FILTER TO SYSTEM
20 ± PASSAGE TO CAMSHAFT REAR BEARING
21 ± RIGHT OIL GALLERY
22 ± PLUG
23 ± OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT
24 ± OIL SUPPLY VIA HOLLOW PUSH ROD SUPPLY IS FROM
OIL GALLERY METERED THROUGH HYDRAULIC TAPPET
25 ± OIL SUPPLY FROM HOLLOW PUSH ROD
Fig. 5 Exhaust ManifoldsÐV-8 Gas Engines Typical
1 ± EXHAUST MANIFOLD (LEFT)
2 ± BOLTS & WASHERS
3 ± NUTS & WASHERS
4 ± EXHAUST MANIFOLD (RIGHT)
5 ± BOLTS & WASHERS
Fig. 6 Intake Manifold and Throttle BodyÐV-8 Gas
Engines Typical
1 ± FUEL RAIL ASSEMBLY
2 ± FUEL RAIL MOUNTING BOLTS
3 ± FUEL RAIL CONNECTING HOSES
DN5.2L ENGINE 9 - 89
DESCRIPTION AND OPERATION (Continued)