DODGE DURANGO 1999 1.G Repair Manual

Downloaded from www.Manualslib.com manuals search engine CAUTION: Care should be taken not to damage
camshaft target wheel. Do not hold target wheel
while loosening or tightening camshaft sprocket.
Do not place the target wheel near a magnetic
source of any kind. A damaged or magnetized tar-
get wheel could cause a vehicle no start condition.
CAUTION: Do not forcefully rotate the camshafts or
crankshaft independently of each other. Damaging
intake valve to piston contact will occur. Ensure
negative battery cable is disconnected to guard
against accidental starter engagement.
(13) Remove left and right camshaft sprocket bolts.
(14) While holding the left camshaft steel tube
with adjustable pliers, (Fig. 80) remove the left cam-
shaft sprocket. Slowly rotate the camshaft approxi-
mately 15 degrees clockwise to a neutral position.
(15) While holding the right camshaft steel tube
with adjustable pliers, (Fig. 81) remove the right
camshaft sprocket. Slowly rotate the camshaft
approximately 45 degrees counterclockwise to a neu-
tral position.
(16) Remove idler sprocket assembly bolt.
(17) Slide the idler sprocket assembly and crank
sprocket forward simultaneously to remove the pri-
mary and secondary chains.
(18) Remove both pivoting tensioner arms and
chain guides.(19) Remove chain tensioner.
Fig. 79 Camshaft Position SensorÐRemoval
1 ± CRANKSHAFT POSITION SENSOR
2 ± CYLINDER HEAD COVER
3 ± CAMSHAFT POSITION SENSOR
4 ± RIGHT SIDE CYLINDER BLOCKFig. 80 Camshaft RotationÐLeft Side
1 ± CAMSHAFT SPROCKET AND CHAIN
2 ± ADJUSTABLE PLIERS
3 ± CAMSHAFT
Fig. 81 Camshaft RotationÐRight Side
1 ± ADJUSTABLE PLIERS
2 ± CAMSHAFT DOWEL
DN4.7L ENGINE 9 - 51
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSPECTION OF COMPONENTS
Inspect the following components:
²Sprockets for excessive tooth wear. Some tooth
markings are normal and not a cause for sprocket
replacement.
²Idler sprocket assembly bushing and shaft for
excessive wear.
²Idler sprocket assembly spline joint. The joint
should be tight with no backlash or axial movement.
²Chain guides and tensioner arms. Replace these
parts if grooving in plastic face is more than 1 mm
(0.039 in.) deep. If plastic face is severely grooved or
melted, the tensioner lube jet may be clogged. The
tensioner should be replaced.
²secondary chain tensioner piston and ratcheting
device. Inspect for evidence of heavy contact between
tensioner piston and tensioner arm. If this condition
exist the tensioner tensioner arm and chain should
be replaced.²Primary chain tensioner plastic faces. Replace as
required.
INSTALLATION
(1) Using a vise, lightly compress the secondary
chain tensioner piston until the piston step is flush
with the tensioner body. Using a pin or suitable tool,
release ratchet pawl by pulling pawl back against
spring force through access hole on side of tensioner.
While continuing to hold pawl back, Push ratchet
device to approximately 2 mm from the tensioner
body. Install Special Tool 8514 lock pin into hole on
front of tensioner. Slowly open vise to transfer piston
spring force to lock pin (Fig. 83).
(2) Position primary chain tensioner over oil pump
and insert bolts into lower two holes on tensioner
bracket. Tighten bolts to 28 N´m (250 in. lbs.).
Fig. 82 Timing Chain System
1 ± RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN
2 ± SECONDARY TIMING CHAIN TENSIONER
3 ± SECONDARY TENSIONER ARM
4 ± LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN
5 ± CHAIN GUIDE
6 ± TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN7 ± PRIMARY CHAIN
8 ± IDLER SPROCKET
9 ± CRANKSHAFT SPROCKET
10 ± PRIMARY CHAIN TENSIONER
11 ± TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
12 ± SECONDARY TENSIONER ARM
9 - 52 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CAUTION: Overtightening the tensioner arm torxT
bolt can cause severe damage to the cylinder head.
Tighten torxTbolt to specified torque only.
(3) Install right side chain tensioner arm. Apply
MopartLock N, Seal to torxtbolt, tighten bolt to 17
N´m (150 in. lbs.).
NOTE: The silver bolts retain the guides to the cyl-
inder heads and the black bolts retain the guides to
the engine block.
(4) Install the left side chain guide. Tighten the
bolts to 28 N´m (250 in. lbs.).
CAUTION: Overtightening the tensioner arm torxT
bolt can cause severe damage to the cylinder head.
Tighten torxTbolt to specified torque only.
(5) Install left side chain tensioner arm. Apply
MopartLock N, Seal to torxtbolt, tighten bolt to 17
N´m (150 in. lbs.).
(6) Install the right side chain guide. Tighten the
bolts to 28 N´m (250 in. lbs.).
(7) Install both secondary chains onto the idler
sprocket. Align two plated links on the secondary
chains to be visible through the two lower openings
on the idler sprocket (4 o'clock and 8 o'clock). Oncethe secondary timing chains are installed, position
special tool 8515 to hold chains in place for installa-
tion (Fig. 84).
(8) Align primary chain double plated links with
the timing mark at 12 o'clock on the idler sprocket.
Align the primary chain single plated link with the
timing mark at 6 o'clock on the crankshaft sprocket
(Fig. 82).
(9) Lubricate idler shaft and bushings with clean
engine oil.
(10) Install all chains, crankshaft sprocket, and
idler sprocket as an assembly (Fig. 85). After guiding
both secondary chains through the block and cylinder
head openings, affix chains with a elastic strap or the
equivalent, This will maintain tension on chains to
aid in installation.
NOTE: It will be necessary to slightly rotate cam-
shafts for sprocket installation.
(11) Align left camshaft sprocket ªLº dot to plated
link on chain.
(12) Align right camshaft sprocket ªRº dot to
plated link on chain.
CAUTION: Remove excess oil from the camshaft
sprocket bolt. Failure to do so can result in over-
torque of bolt resulting in bolt failure.
Fig. 83 Resetting Secondary Chain Tensioners
1 ± VISE
2 ± INSERT LOCK PIN
3 ± RATCHET PAWL
4 ± RATCHET
5 ± PISTON
Fig. 84 Installing Secondary Timing Chains on Idler
Sprocket
1 ± LOCK ARM
2 ± RIGHT CAMSHAFT CHAIN
3 ± SECONDARY CHAINS RETAINING PINS (4)
4 ± IDLER SPROCKET
5 ± LEFT CAMSHAFT CHAIN
6 ± SPECIAL TOOL 8515
DN4.7L ENGINE 9 - 53
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (13) Remove Special Tool 8515, then attach both
sprockets to camshafts. Remove excess oil from bolts,
then Install sprocket bolts, but do not tighten at this
time.
(14) Verify that all plated links are aligned with
the marks on all sprockets and the ªV8º marks on
camshaft sprockets are at the 12 o'clock position (Fig.
82).
CAUTION: Ensure the plate between the left sec-
ondary chain tensioner and block is correctly
installed.
(15) Install both secondary chain tensioners.
Tighten bolts to 28 N´m (250 in. lbs.).
NOTE: Left and right secondary chain tensioners
are not common.
(16) Before installing idler sprocket bolt, lubricate
washer with oil, and tighten idler sprocket assembly
retaining bolt to 34 N´m (25 ft. lbs.).
(17) Remove all locking pins (3) from tensioners.
CAUTION: After pulling locking pins out of each
tensioner, DO NOT manually extend the tensioner(s)
ratchet. Doing so will over tension the chains,
resulting in noise and/or high timing chain loads.
(18) Using Special Tool 6958, Spanner with Adap-
tor Pins 8346, tighten left (Fig. 86) and right (Fig.
87). camshaft sprocket bolts to 122 N´m (90 ft. lbs.).(19) Rotate engine two full revolutions. Verify tim-
ing marks are at the follow locations:
²primary chain idler sprocket dot is at 12 o'clock
(Fig. 82)
²primary chain crankshaft sprocket dot is at 6
o'clock (Fig. 82)
²secondary chain camshaft sprockets ªV8º marks
are at 12 o'clock (Fig. 82)
(20) Lubricate all three chains with engine oil.
(21) After installing all chains, it is recommended
that the idler gear end play be checked (Fig. 88). The
end play must be within 0.10±0.25 mm (0.004±0.010
in.). If not within specification, the idler gear must be
replaced.
(22) Install timing chain cover and crankshaft
damper. Refer to procedures in this section.
(23) Install cylinder head covers. Refer to proce-
dures in this section.
NOTE: Before installing threaded plug in right cyl-
inder head, the plug must be coated with sealant to
prevent leaks.
Fig. 85 Installing Idler Gear, Primary and Secondary
Timing Chains
1 ± SPECIAL TOOL 8515
2 ± PRIMARY CHAIN IDLER SPROCKET
3 ± CRANKSHAFT SPROCKET
Fig. 86 Tightening Left Side Camshaft Sprocket Bolt
1 ± TORQUE WRENCH
2 ± CAMSHAFT SPROCKET
3 ± LEFT CYLINDER HEAD
4 ± SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
9 - 54 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (24) Coat the large threaded access plug with
MopartThread Sealant with Teflon, then install
into the right cylinder head and tighten to 81 N´m
(60 ft. lbs.) (Fig. 77).(25) Install the oil fill housing.
(26) Install access plug in left cylinder head (Fig.
77).
(27) Install power steering pump. Refer to Group
19, Steering for procedure.
(28) Install radiator fan shroud. Refer to Group 7,
Cooling System for procedure.
(29) Fill cooling system. Refer to Group 7, Cooling
System for coolant fill procedure.
(30) Connect negative cable to battery.
IDLER SHAFTÐTIMING DRIVE
REMOVAL
(1) Remove the timing chain and sprockets. Refer
to procedure in this section.
NOTE: To remove the idler shaft, it is necessary to
tap threads into the shaft to install the removal tool.
(2) Using a 12 mm X 1.75 tap, cut threads in the
idler shaft center bore (Fig. 89).
(3) Cover the radiator core with a suitable cover.
CAUTION: Use care when removing idler shaft, DO
NOT strike the radiator cooling fins with the slide
hammer.
(4) Using Special Tool 8517 Slide Hammer, remove
the idler shaft (Fig. 90).
Fig. 87 Tightening Right Side Camshaft Sprocket
Bolt
1 ± TORQUE WRENCH
2 ± SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 ± LEFT CAMSHAFT SPROCKET
4 ± RIGHT CAMSHAFT SPROCKET
Fig. 88 Measuring Idler Gear End Play
1 ± IDLER SPROCKET ASSEMBLY
2 ± DIAL INDICATOR
Fig. 89 Tapping Idler Shaft For Special Tool 8517
1 ± IDLER SHAFT
2 ± TAP 12mm X 1.75
DN4.7L ENGINE 9 - 55
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
(1) Thoroughly clean the idler shaft bore.
(2) Position the idler shaft in the bore.
NOTE: The two lubrication holes in the idler shaft
do not require any special alignment.
NOTE: Before using the retaining bolt to install the
idler shaft, coat the threads and the pilot on the
idler shaft with clean engine oil.
(3) Using the primary idler sprocket retaining bolt
and washer, carefully draw the idler shaft into the
bore until fully seated.
(4) Coat the idler shaft with clean engine oil and
install the timing chains and sprockets. Refer to pro-
cedure in this section.
CAMSHAFTSÐIN VEHICLE
LEFT CAMSHAFT
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.CAUTION: When removing the cam sprocket, tim-
ing chains or camshaft, Failure to use Special Tool
8350 will result in hydraulic tensioner ratchet over
extension, requiring timing chain cover removal to
reset the tensioner ratchet.
(1) Remove cylinder head cover. Refer to Cylinder
Head Cover in this section.
(2) Set engine to TDC cylinder #1, camshaft
sprocket V8 marks at the 12 o'clock position.
(3) Mark one link on the secondary timing chain
on both sides of the V8 mark on the camshaft
sprocket to aid in installation.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel (Located on the right side camshaft
sprocket) for any reason, Severe damage will occur
to the target wheel resulting in a vehicle no start
condition.
(4) Loosen butDO NOTremove the camshaft
sprocket retaining bolt. Leave the bolt snug against
the sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
(5) Position Special Tool 8350 timing chain wedge
between the timing chain strands, tap the tool to
securely wedge the timing chain against the ten-
sioner arm and guide (Fig. 91).
(6) Hold the camshaft with adjustable pliers while
removing the camshaft sprocket bolt and sprocket
(Fig. 92).
(7) Using the pliers, gently allow the camshaft to
rotate 15É clockwise until the camshaft is in the neu-
tral position (no valve load).
(8) Starting at the outside working inward, loosen
the camshaft bearing cap retaining bolts 1/2 turn at
a time. Repeat until all load is off the bearing caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
before removing camshaft.
Fig. 90 Removing Idler Shaft
1 ± IDLER SHAFT
2 ± SPECIAL TOOL 8517
9 - 56 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (9) Remove the camshaft bearing caps and the
camshaft.INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
NOTE: Position the left side camshaft so that the
camshaft sprocket dowel is near the 1 o'clock posi-
tion, 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¤2turn increments, tighten the
bearing cap retaining bolts starting with the middle
cap working outward (Fig. 93).
(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. 94).
(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. 95).
Fig. 91 Securing Timing Chain Tensioners Using Timing Chain Wedge
1 ± LEFT CYLINDER HEAD
2 ± RIGHT CYLINDER HEAD3 ± SPECIAL TOOL 8350 WEDGE
4 ± SPECIAL TOOL 8350 WEDGE
Fig. 92 Camshaft Sprocket and Chain
1 ± CAMSHAFT SPROCKET AND CHAIN
2 ± ADJUSTABLE PLIERS
3 ± CAMSHAFT
DN4.7L ENGINE 9 - 57
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine 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 bolt, then install the
camshaft sprocket retaining bolt and hand tighten.
(9) Remove Special Tool 8350 timing chain wedge
(Fig. 91).
(10) Using Special Tool 6958 spanner wrench with
adapter pins 8346 (Fig. 96), torque the camshaft
sprocket retaining bolt to 122 N´m (90 ft. lbs.).
(11) Install the cylinder head cover.
RIGHT CAMSHAFT
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, tim-
ing chains or camshaft, Failure to use special tool
8350 will result in hydraulic tensioner ratchet over
extension, Requiring timing chain cover removal to
re-set the tensioner ratchet.
(1) Remove the cylinder head covers. Refer to Cyl-
inder Head Cover in this section.
Fig. 94 Timing Chain to Sprocket Alignment
1 ± LEFT CYLINDER HEAD
2 ± RIGHT CYLINDER HEAD
Fig. 93 Camshaft Bearing Caps Tightening
Sequence
9 - 58 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (2) Set engine to TDC cylinder #1, camshaft
sprocket V8 marks at the 12 o'clock position.
(3) Mark one link on the secondary timing chain
on both sides of the V8 mark on the camshaft
sprocket to aid in installation.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason, Severe damage will occur
to the target wheel. A damaged target wheel could
cause a vehicle no start condition.
(4) Loosen butDO NOTremove the camshaft
sprocket retaining bolt. Leave bolt snug against
sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
(5) Position Special Tool 8350 timing chain wedge
between the timing chain strands. Tap the tool to
securely wedge the timing chain against the ten-
sioner arm and guide (Fig. 97).
(6) Remove the camshaft position sensor (Fig. 98).(7) Hold the camshaft with adjustable pliers while
removing the camshaft sprocket bolt and sprocket
(Fig. 99).
(8) Using the pliers, gently allow the camshaft to
rotate 45É counter-clockwise until the camshaft is in
the neutral position (no valve load).
(9) Starting at the outside working inward, loosen
the camshaft bearing cap retaining bolts 1/2 turn at
a time. Repeat until all load is off the bearing caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
before removing camshaft.
(10) Remove the camshaft bearing caps and the
camshaft.
Fig. 95 Camshaft Sprocket Installation
1 ± ADJUSTABLE PLIERS
2 ± CAMSHAFT DOWEL
Fig. 96 Tightening Left Side Cam Sprocket
Retaining Bolt
1 ± TORQUE WRENCH
2 ± CAMSHAFT SPROCKET
3 ± LEFT CYLINDER HEAD
4 ± SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
DN4.7L ENGINE 9 - 59
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine Fig. 97 Securing Timing Chain Tensioners Using Timing Chain Wedge
1 ± LEFT CYLINDER HEAD
2 ± RIGHT CYLINDER HEAD3 ± SPECIAL TOOL 8350 WEDGE
4 ± SPECIAL TOOL 8350 WEDGE
Fig. 98 Camshaft Position Sensor
1 ± CRANKSHAFT POSITION SENSOR
2 ± CYLINDER HEAD COVER
3 ± CAMSHAFT POSITION SENSOR
4 ± RIGHT SIDE CYLINDER BLOCKFig. 99 Camshaft Sprocket and Chain
1 ± ADJUSTABLE PLIERS
2 ± SPROCKET BOLT
3 ± CAMSHAFT SPROCKET AND CHAIN
4 ± CAMSHAFT
9 - 60 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)