drain bolt DODGE DURANGO 1999 1.G Owner's Manual

Downloaded from www.Manualslib.com manuals search engine After the distributor has been installed, its rota-
tional position must be set using theSET SYNC
mode of the DRB scan tool. Refer to Checking Dis-
tributor Position following the Distributor Installa-
tion section in Group 8D, Ignition system.
Do not attempt to adjust ignition timing by
rotating the distributor. It has no effect on igni-
tion timing. Adjusting distributor position will
effect fuel synchronization only.
OIL PAN
REMOVAL
2WD
(1) Disconnect the negative cable from the battery.
(2) Remove air cleaner assembly.
(3) Remove engine oil dipstick.
(4) Disconnect distributor cap and position away
from cowl.
(5) Remove the fan shroud. Refer to COOLING
SYSTEM.
(6) Disconnect throttle valve cable from throttle
body and mounting bracket (Fig. 62A).
(7) Raise vehicle.
(8) Drain engine oil.
(9) Remove exhaust pipe from exhaust manifolds.
(10) Remove engine mount insulator through bolts.
(11) Raise engine by way of oil pan using a block
of wood between the jack and oil pan.
(12) When engine is high enough, place mount
through bolts in the engine mount attaching points
on the frame brackets.
(13) Lower engine so bottom of engine mounts rest
on the replacement bolts placed in the engine mount
frame brackets.
(14) Remove transmission to engine braces.
(15) Remove starter. Refer to STARTING SYS-
TEMS.(16) Remove transmission torque converter inspec-
tion cover.
(17) Disconnect rear support cushion from cross-
member.
(18) Raise rear of transmission away from cross-
member.
(19) Remove oil pan and one-piece gasket.
4WD
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove front driving axle. Refer to DIFFER-
ENTIAL and DRIVELINE.
(6) Remove both engine mount support brackets.
(7) Remove transmission torque converter inspec-
tion cover.
(8) Remove oil pan and one-piece gasket.
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
installation and removal with a screwdriver (Fig. 63).
Fig. 62 Position of Oil Pump Shaft Slot
1 ± DISTRIBUTOR DRIVE
Fig. 62A Throttle Valve Cable Removal/Installation
1 ± TRANSMISSION THROTTLE VALVE CABLE BRACKET
2 ± AIR INLET DUCT
3 ± TRANSMISSION THROTTLE VALVE CABLE
DN5.2L ENGINE 9 - 115
REMOVAL AND INSTALLATION (Continued)
2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99 December, 1999

Downloaded from www.Manualslib.com manuals search engine (2)Install the dowels in the cylinder block (Fig. 64).
(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 to 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. 62A).
(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
installation and removal with a screwdriver (Fig. 63).
(2) Install the dowels in the cylinder block (Fig.
64).
(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.
Fig. 63 Fabrication of Alignment Dowels
1 ± 1 1/2º x 5/16º BOLT
2 ± DOWEL
3 ± SLOT
Fig. 64 Position of Dowels in Cylinder Block
1 ± DOWEL
2 ± DOWEL
3 ± DOWEL
4 ± DOWEL
9 - 115A 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)
2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99 December, 1999

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 CYLINDER HEAD COVER GASKET
DESCRIPTION
The cylinder head cover gasket is a steel-backed
silicone gasket, designed for long life usage (Fig. 7).
OPERATION
The steel-backed silicone gasket is designed to seal
the cylinder head cover for long periods of time
through extensive heat and cold, without failure. The
gasket is designed to be reusable.
CYLINDER HEAD
DESCRIPTION
The cast iron cylinder heads (Fig. 8) are mounted
to the cylinder block using ten bolts. The spark plugs
are located in the peak of the wedge between the
valves.
OPERATION
The cylinder head closes the combustion chamber
allowing the pistons to compress the air fuel mixture
to the correct ratio for ignition. The valves located in
the cylinder head open and close to either allow clean
air into the combustion chamber or to allow the
exhaust gases out, depending on the stroke of the
engine.
VALVES AND VALVE SPRINGS
DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 48.768 mm (1.92 inches) in
diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch)
wafer interia welded to the tip for durability. These
valves are not splayed.
ENGINE OIL PAN
DESCRIPTION
The stamped steel engine oil pan is located at the
bottom of the engine, and contains a drain plug for
draining the engine oil.
OPERATION
The oil pan holds the engine oil and seals and pro-
tects the engine lower components from contami-
nates.
CRANKSHAFT OIL SEALS
DESCRIPTION
The crankshaft rear seal is a two piece viton seal.
The crankshaft front seal is a one piece viton seal
with a steel housing. The front seal is located in the
engine front cover. One part of the two piece rear
seal is located in a slot in the number five (5) crank-
shaft main bore, the second part of the two piece seal
is located in the number five (5) main bearing cap.
OPERATION
The crankshaft seals prevent oil from leaking from
around the crankshaft, either from the rear of the
engine or from the engine front cover.
PISTON AND CONNECTING ROD
DESCRIPTION
The pistons are made of aluminum and have three
ring grooves, the top two grooves are for the compres-
sion rings and the bottom groove is for the oil control
ring. The connecting rods are forged steel and are
coined prior to heat treat. The piston pins are press
fit.
Fig. 7 Cylinder Head Cover Gasket V-8 Gas Engines
1 ± CYLINDER HEAD COVER GASKET
Fig. 8 Cylinder Head AssemblyÐV-8 Gas Engines
1 ± EXHAUST VALVE
2 ± SPARK PLUGS
3 ± EXHAUST VALVES
4 ± SPARK PLUGS
5 ± EXHAUST VALVE
6 ± INTAKE VALVES
7 ± INTAKE VALVES
9 - 140 5.9L ENGINEDN
DESCRIPTION AND OPERATION (Continued)

Downloaded from www.Manualslib.com manuals search engine REMOVALÐ4WD
(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. 39).
(5) Raise rear of transmission SLIGHTLY.
(6) Remove bolts holding the insulator to the insu-
lator bracket (Fig. 39). Remove the insulator.
INSTALLATIONÐ4WD
(1) If the insulator bracket was removed, install
the bracket to the transmission (Fig. 39). 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) Remove the battery.
(3) Drain cooling system. Refer to COOLING SYS-
TEM.
(4) Remove the air cleaner assembly and air inlet
hose.
(5) Disconnect the radiator and heater hoses.
(6) Set fan shroud aside.
(7) Remove the vacuum lines.
(8) Remove the distributor cap and wiring.
(9) Disconnect the accelerator linkage.
(10) Remove throttle body.
(11) Perform the Fuel System Pressure release
procedure Refer to FUEL SYSTEM.
(12) Disconnect the fuel lines.
(13) Disconnect the starter wires.
(14) Disconnect the oil pressure wire.
Fig. 37 Engine Mount Insulator at FrameÐ4WD
Vehicles
1 ± NUT
2 ± ENGINE SUPPORT BRACKET
3 ± INSULATOR
4 ± NUT
5 ± THROUGH BOLT
6 ± FRAME
7 ± FRONT AXLE
Fig. 38 Rear InsulatorÐ2WD Vehicles
1 ± ENGINE SUPPORT BRACKET
2 ± THROUGH BOLT
3 ± CROSSMEMBER
4 ± INSULATOR
5 ± TRANSMISSION EXTENSION
DN5.9L ENGINE 9 - 161
REMOVAL AND INSTALLATION (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 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 (2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 52).
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 244 N´m (180 ft. lbs.) torque.
(4) Install the accessory drive belt.
(5) Position the fan shroud and install the bolts.
Tighten the retainer bolts to 11 N´m (95 in. lbs.)
torque.
(6) Install the cooling fan.
(7) Connect the battery negative cable.
TIMING CHAIN COVER
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (refer to Group 7, Cooling
System).
(3) Remove the serpentine belt (refer to Group 7,
Cooling System).
(4) Remove water pump (refer to Group 7, Cooling
System).
(5) Remove power steering pump (refer to Group
19, Steering).
(6) Remove vibration damper.
(7) Remove fuel lines (refer to Group 14, Fuel Sys-
tem).
(8) Loosen oil pan bolts and remove the front bolt
at each side.
(9) Remove the cover bolts.
(10) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
(11) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal surface of cover (Fig. 53).
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) The water pump mounting surface must be
cleaned.(3) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar Silicone Rubber Adhe-
sive Sealant, or equivalent, at the joint between tim-
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.
(4) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 54). Seat
the oil seal in the groove of the tool.
(5) Position the seal and tool onto the crankshaft
(Fig. 55).
(6) Tighten the 4 lower chain case cover bolts to
13N´m (10 ft.lbs.) to prevent the cover from tipping
during seal installation.
(7) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 56).
(8) Loosen the 4 bolts tightened in step 4 to allow
realignment of front cover assembly.
(9) Tighten chain case cover bolts to 41 N´m (30 ft.
lbs.) torque. Tighten oil pan bolts to 24 N´m (215 in.
lbs.) torque.
Fig. 52 Vibration Damper Installation
1 ± SPECIAL TOOL C-3688
Fig. 53 Removal of Front Crankshaft Oil Seal
Fig. 54 Placing Oil Seal on Installation Tool 6635
1 ± CRANKSHAFT FRONT OIL SEAL
2 ± INSTALL THIS END INTO SPECIAL TOOL 6635
DN5.9L ENGINE 9 - 169
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 67).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight-
ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal-
lation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 67).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing caps. Clean and oil the bolts.
Tighten the capbolts to 115 N´m (85 ft. lbs.) torque.
(4) Install the oil pump.
(5) Install the oil pan.
(6) Start engine check for leaks.
OIL PAN
REMOVAL
2WD
(1) Disconnect the negative cable from the battery.
(2) Remove air cleaner assembly.
(3) Remove engine oil dipstick.(4) Disconnect distributor cap and position away
from cowl.
(5) Remove the fan shroud. Refer to COOLING
SYSTEM.
(6) Disconnect throttle valve cable from throttle
body and mounting bracket (Fig. 67A).
(7) Raise vehicle.
(8) Drain engine oil.
(9) Remove exhaust pipe from exhaust manifolds.
(10) Remove engine mount insulator through bolts.
(11) Raise engine by way of oil pan using a block of
wood between the jack and oil pan.
(12) When engine is high enough, place mount
through bolts in the engine mount attaching points on
the frame brackets.
(13) Lower engine so bottom of engine mounts rest
on the replacement bolts placed in the engine mount
frame brackets.
(14) Remove transmission to engine braces.
(15) Remove starter. Refer to STARTING SYS-
TEMS.
(16) Remove transmission torque converter inspec-
tion cover.
(17) Disconnect rear support cushion from cross-
member.
(18) Raise rear of transmission away from cross-
member.
(19) Remove oil pan and one-piece gasket.
4WD
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove front driving axle. Refer to DIFFEREN-
TIAL and DRIVELINE.
(6) Remove both engine mount support brackets.
(7) Remove transmission torque converter inspec-
tion cover.
(8) Remove oil pan and one-piece gasket.
Fig. 67 Upper Main Bearing Removal and
Installation with Tool C-3059
1 ± SPECIAL TOOL C-3059
2 ± BEARING
3 ± SPECIAL TOOL C-3059
4 ± BEARING
Fig. 67A Throttle Valve Cable Removal/Installation
1 ± TRANSMISSION THROTTLE VALVE CABLE BRACKET
2 ± AIR INLET DUCT
3 ± TRANSMISSION THROTTLE VALVE CABLE
9 - 174 5.9L ENGINEDN
REMOVAL AND INSTALLATION (Continued)
2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99 December, 1999

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