4x4 DODGE DURANGO 1999 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine ENGINE
TABLE OF CONTENTS
page page
4.7L ENGINE.............................. 1
5.2L ENGINE............................. 865.9L ENGINE............................ 135
4.7L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ENGINE.................................2
ENGINE LUBRICATION SYSTEM..............3
CYLINDER BLOCK.........................5
CRANKSHAFT............................5
PISTON AND CONNECTING ROD.............5
CYLINDER HEAD..........................5
VALVE GUIDES...........................5
VALVES.................................5
VALVE STEM SEAL........................5
VALVE SPRING...........................6
HYDRAULIC LASH ADJUSTER...............6
TIMING DRIVE SYSTEM....................6
CAMSHAFT..............................6
ROCKER ARM............................6
CYLINDER HEAD COVER...................6
OILPAN.................................7
STRUCTURAL DUST COVER................7
INTAKE MANIFOLD........................7
EXHAUST MANIFOLD......................7
DIAGNOSIS AND TESTING
ENGINE DIAGNOSISÐINTRODUCTION.........7
SERVICE DIAGNOSISÐPERFORMANCE.......8
SERVICE DIAGNOSISÐMECHANICAL.........10
SERVICE DIAGNOSISÐLUBRICATION.........11
INTAKE MANIFOLD LEAKAGE DIAGNOSIS.....11
CYLINDER COMPRESSION PRESSURE TEST . . 11
CYLINDER HEAD GASKET FAILURE
DIAGNOSIS...........................12
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST........................12
ENGINE OIL LEAK INSPECTION.............13
REAR SEAL AREA LEAKSÐINSPECTION......14
HYDRAULIC LASH ADJUSTER NOISE
DIAGNOSIS...........................14
CHECKING ENGINE OIL PRESSURE..........15SERVICE PROCEDURES
FORM-IN-PLACE GASKETS.................15
ENGINE OIL.............................16
REPAIR DAMAGED OR WORN THREADS......17
CYLINDER BOREÐHONING................18
HYDROSTATIC LOCK.....................18
VALVE SERVICE.........................19
ENGINE TIMINGÐVERIFICATION............19
TIMING CHAINÐMEASURING WEAR.........22
PISTONSÐFITTING.......................22
PISTON RINGSÐFITTING..................24
CONNECTING ROD BEARINGSÐFITTING.....25
CRANKSHAFT MAIN BEARINGS.............27
REMOVAL AND INSTALLATION
ENGINE MOUNTSÐLEFT AND RIGHT.........28
ENGINE MOUNTÐREAR...................29
STRUCTURAL COVER.....................30
ENGINE ASSEMBLY.......................31
INTAKE MANIFOLD.......................35
EXHAUST MANIFOLDS....................36
CYLINDER HEAD COVER..................38
ROCKER ARMS..........................40
CYLINDER HEADS........................41
VALVE SPRINGS AND SEALS...............46
HYDRAULIC LASH ADJUSTER..............46
CRANKSHAFT DAMPER...................47
TIMING CHAIN COVER....................48
TIMING CHAIN AND SPROCKETS............49
IDLER SHAFTÐTIMING DRIVE..............55
CAMSHAFTSÐIN VEHICLE.................56
CRANKSHAFT MAIN BEARINGS.............61
OIL PAN 4X2 VEHICLE.....................61
OIL PAN 4X4 VEHICLE.....................64
PISTON AND CONNECTING ROD............65
CRANKSHAFT...........................67
FLEXPLATE.............................69
DNENGINE 9 - 1

Downloaded from www.Manualslib.com manuals search engine nal diameter specification (Main Bearing Fitting
Chart). Select inserts required to obtain the specified
bearing-to-journal clearance.
Install the crankshaft into the cylinder block. Refer
to Crankshaft in this section for procedure.
CRANKSHAFT MAIN BEARING SELECTION
(1) Service main bearings are available in three
grades. The chart below identifies the three service
grades available.
REMOVAL AND INSTALLATION
ENGINE MOUNTSÐLEFT AND RIGHT
REMOVAL
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the fan blade, fan clutch and
fan shroud before raising engine. Failure to do so
may cause damage to the fan blade, fan clutch and
fan shroud.
(2) Remove the fan blade, fan clutch and fan
shroud. Refer to Group 7. for procedure.
(3) Remove the engine oil filter.
(4) Support the engine with a suitable jack and a
block of wood across the full width of the engine oil
pan.
(5) Remove the four (4) cylinder block-to-insulator
mount bolts and the nut from the engine insulator
mount through bolt (4x2 Vehicles only) (Fig. 32) (Fig.
33).
(6) Remove the three (3) cylinder block-to-insulator
mount bolts and loosen the nut from the engine insu-
lator mount through bolt (4x4 Vehicles only) (Fig. 34)
(Fig. 35).
(7) Using the jack, raise the engine high enough to
remove the engine insulator mount through bolt and
the insulator mount.
INSTALLATION
(1) Position the insulator mount and install the
insulator mount through bolt.
(2) Lower the engine until the four cylinder block-
to-insulator mount bolts can be installed.
(3) Remove the jack and block of wood.
(4) Torque the cylinder block-to-insulator mount
bolts to 61N´m ( 45 ft. lbs.).
(5) Install and torque the through bolt retaining
nut to 61N´m (45 ft. lbs.).
(6) Install the fan blade, fan clutch and fan
shroud.
GRADE SIZE mm
(in.)FOR USE WITH
MARKING JOURNAL SIZE
A.008 mm U/S 63.488-63.496 mm
(.0004 in.)
U/S(2.4996-2.4999 in.)
BSTANDARD 63.496-63.504 mm
(2.4996-2.4999 in.)
C.008 mm O/S 63.504-63.512 mm
(.0004 in.)
O/S(2.5002-2.5005 in.)
Fig. 32 Engine Insulator Mount 4x2 VehicleÐLeft
Side
1 ± ENGINE INSULATOR MOUNT-LEFT SIDE
2 ± MOUNTING BOLT
Fig. 33 Engine Insulator Mount 4x2 VehicleÐRight
Side
1 ± ENGINE INSULATOR MOUNT-RIGHT SIDE
2 ± MOUNTING BOLT
9 - 28 4.7L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine ENGINE MOUNTÐREAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Using a suitable jack, support transmission.
(3) Remove the nut from the insulator mount
through bolt (Manual transmission and 4x2 auto-
matic transmission only) (Fig. 36) (Fig. 37).(4) Remove the four bolts and washers retaining
the mount to the transmission (4x4 automatic trans-
mission only) (Fig. 38).
(5) Raise the transmission enough to remove the
through bolt (Manual transmission and 4x2 auto-
matic transmission only) (Fig. 36) (Fig. 37).
(6) Raise the transmission and remove the bolts
retaining the mount to the crossmember (4x4 auto-
matic transmission only) (Fig. 38).
(7) Remove the two nuts retaining the isolator to
the crossmember (Manual transmission and 4x2
automatic transmission only) (Fig. 36) (Fig. 37).
(8) Remove the bolts (two bolts manual transmis-
sion)(three bolts 4x2 automatic transmission) retain-
ing the insulator bracket to the transmission.
INSTALLATION
(1) Follow the removal procedure in the reverse
order.
(2) Tighten the through bolt retaining nut to 102
N´m (75 ft. lbs.).
(3) Tighten the isolator bracket to transmission
retaining bolts (Manual transmission and 4x2 auto-
matic transmission only) to 41 N´m (30 ft. lbs.).
(4) Tighten the mount bracket to transmission
retaining bolts (4x4 automatic transmission only) to
68 N´m (50 ft. lbs.).
(5) Tighten the isolator mount to crossmember
retaining nuts (Manual transmission and 4x2 auto-
matic transmission only) to 28 N´m (250 in. lbs.).
Fig. 34 Engine Insulator Mount 4x4 VehicleÐLeft
Side
1 ± ENGINE INSULATOR MOUNT-LEFT SIDE
2 ± MOUNTING BOLT
Fig. 35 Engine Insulator Mount 4x4 VehicleÐRight
Side
1 ± ENGINE INSULATOR MOUNT-RIGHT SIDE
2 ± MOUNTING BOLT
Fig. 36 Engine Rear MountÐ4X2 Automatic
Transmission
1 ± ENGINE REAR MOUNT
2 ± BOLT
3 ± NUT
4 ± THROUGH BOLT NUT
5 ± TRANSMISSION
DN4.7L ENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (6) Tighten the mount bracket to crossmember
retaining bolts (4x4 automatic transmission only) to
28 N´m (250 in. lbs.).
STRUCTURAL COVER
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the left hand exhaust pipe from
exhaust manifold. Refer to Group 11, Exhaust Sys-
tem.
(3) Loosen the right hand exhaust manifold-to-ex-
haust pipe retaining bolts.
(4) Remove the eight bolts retaining structural
cover (Fig. 39).
(5) Pivot the exhaust pipe downward and remove
the structural cover.
INSTALLATION
CAUTION: The structural cover must be installed
as described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Position the structural cover in the vehicle.
(2) Install all four bolts retaining the cover-to-en-
gine. DO NOT tighten the bolts at this time.
(3) Install the four cover-to-transmission bolts. Do
NOT tighten at this time.
CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starting with the two rear cover-to-engine
bolts, tighten bolts (1) (Fig. 39) to 54 N´m (40 ft. lbs.),
then tighten bolts (2) (Fig. 39) and (3) to 54 N´m ( 40
ft. lbs.) in the sequence shown.
(5) Install the exhaust pipe on left hand exhaust
manifold.
(6) Tighten exhaust manifold-to-exhaust pipe
retaining bolts to 20±26 N´m (15±20 ft. lbs.).
Fig. 37 Engine Rear MountÐ4X2 and 4X4 Manual
Transmission
1 ± THROUGH BOLT
2 ± BOLT
3 ± INSULATOR SUPPORT
4 ± NUT
5 ± NUT AND WASHER
6 ± INSULATOR BRACKET TO TRANSMISSION
Fig. 38 Engine Rear MountÐ4X4 Automatic
Transmission
1 ± TRANSMISSION
2 ± ENGINE REAR MOUNT
3 ± BOLT
Fig. 39 Structural Cover
9 - 30 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine ENGINE ASSEMBLY
REMOVAL
NOTE: This procedure applies to both the 4X2 and
4X4 vehicles, steps that apply to the 4X4 vehicle
only, are identified.
(1) Disconnect the battery negative and positive
cables.
(2) Remove the battery and the battery tray. Refer
to BATTERY.
(3) Raise vehicle on hoist.
(4) Remove exhaust crossover pipe from exhaust
manifolds. Refer to EXHAUST SYSTEM.
(5)4X4 vehiclesDisconnect axle vent tube from
left side engine mount.
(6) Remove the through bolt retaining nut and bolt
from both the left and right side engine mounts (Fig.
40) (Fig. 41).
(7)4X4 vehiclesRemove locknut from left and
right side engine mount brackets (Fig. 41).
(8) Disconnect two ground straps from the lower
left hand side and one ground strap from the lower
right hand side of the engine.
(9) Disconnect crankshaft position sensor. (Fig. 43)
NOTE: The following step applies to 4X4 vehicles
equipped with automatic transmission only.
(10)4X4 vehiclesRemove the axle isolator
bracket from the engine, transmission and the axle
(Fig. 42).
(11) Remove structural cover. Refer to Structural
Cover in this section for procedure.
(12) Remove starter. Refer to STARTING SYS-
TEM.
(13) Drain cooling system. Refer to COOLING
SYSTEM.
(14) Remove torque converter bolts (Automatic
Transmission Only). Refer to TRANSMISSION.
(15) Remove transmission to engine mounting
bolts.
(16) Disconnect the engine block heater power
cable from the block heater, if equipped.(17) Lower vehicle.
(18) Remove throttle body resonator assembly and
air inlet hose.
(19) Disconnect throttle and speed control cables.
(20) Disconnect tube from both the left and right
side crankcase breathers (Fig. 44). Remove breathers
(21) Discharge A/C system. Refer to HEATING and
AIR CONDITIONING.
(22) Remove A/C compressor.
(23) Remove shroud, fan assemblies and accessory
drive belt. Refer to COOLING SYSTEM.
(24) Disconnect transmission oil cooler lines at the
radiator.
(25) Disconnect radiator upper and lower hoses.
Refer to COOLING SYSTEM.
(26) Remove radiator, A/C condenser and transmis-
sion oil cooler as an assembly. Refer to COOLING
SYSTEM.
(27) Remove generator.
(28) Disconnect the two heater hoses from the tim-
ing chain cover and heater core.
(29) Unclip and remove heater hoses and tubes
from the intake manifold (Fig. 45).
(30) Disconnect engine harness at the following
points :
²Intake air temperature (IAT) sensor (Fig. 46)
²Fuel Injectors
SEQUENCE ITEM TORQUE
1BOLT 54 N´m
(Qty 4) (40 ft. lbs.)
2BOLT 54 N´m
(Qty 2) (40 ft. lbs.)
3BOLT 54 N´m
(Qty 2) (40 ft. lbs.)
Fig. 40 Engine Mount Through Bolt and Nut
Removal / InstallationÐ4X2 Vehicles
1 ± LOCKNUT AND WASHER
2 ± ENGINE MOUNT/INSULATOR
3 ± THROUGH BOLT
4 ± FRAME
DN4.7L ENGINE 9 - 31
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine ²Throttle Position (TPS) Switch
²Idle Air Control (IAC) Motor
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold absolute pressure (MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
(31) Disconnect the vacuum lines at the throttle
body and intake manifold.
(32) Release fuel rail pressure then disconnect the
fuel supply quick connect fitting at the fuel rail.
Refer toFUEL SYSTEM for procedure.
(33) Remove power steering pump and position out
of the way.
(34) Install Special Tools 8400 Lifting Studs, into
the cylinder heads.
(35) Install Engine Lifting Fixture Special Tool
8347 (Fig. 47) following these steps.
²Holding the lifting fixture at a slight angle, slide
the large bore in the front plate over the hex portion
of the lifting stud.
²Position the two remaining fixture arms onto
the two Special Tools 8400 Lifting Studs, in the cyl-
inder heads.
²Pull foward and upward on the lifting fixture so
that the lifting stud rest in the slotted area below the
large bore.²Secure the lifting fixture to the three studs
using three 7/16 ± 14 N/C locknuts.
²Make sure the lifting loop in the lifting fixture is
in the last hole (closest to the throttle body) to min-
imize the angle of engine during removal.
(36) Disconnect body ground strap at the right side
cowl (Fig. 48).
(37) Disconnect body ground strap at the left side
cowl (Fig. 49).
NOTE: It will be necessary to support the transmis-
sion in order to remove the engine.
(38) Position a suitable jack under the transmis-
sion.
(39) Remove engine from the vehicle.
INSTALLATION
(1) Position engine in the vehicle.
Position both the left and right side engine mount
brackets and install the through bolts and nuts.
Tighten nuts to4X2 vehicles95 N´m (70 ft. lbs.).
4X4 vehicles102 N´m (75 ft. lbs.).
Fig. 41 Engine Mount Through Bolt and Nut
Removal / InstallationÐ4X4 Vehicles
1 ± ENGINE MOUNT BRACKET (2)
2 ± THROUGH BOLT (2)
3 ± LOCKNUT AND WASHER (2)
4 ± ENGINE ISOLATOR TO ENGINE MOUNT BRACKET STUD (2)
5 ± LOCKNUT (2)
Fig. 42 Axle Isolator Bracket Removal /
InstallationÐ4X4 Vehicles With Automatic
Transmission
1 ± TRANSMISSION
2 ± AXLE ISOLATOR BRACKET
3 ± FRONT AXLE 4X4 VEHICLES
4 ± BOLTS
5 ± ENGINE
9 - 32 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (2)4X4 vehiclesInstall locknuts onto the engine
mount brackets. Tighten locknuts to 41 N´m (30 ft.
lbs.).
(3) Remove jack from under the transmission.
(4) Remove Engine Lifting Fixture Special Tool
8347 (Fig. 47).
(5) Remove Special Tools 8400 Lifting Studs.
(6) Position generator wiring behind the oil dip-
stick tube, then install the oil dipstick tube upper
mounting bolt.
(7) Connect both left and right side body ground
straps.(8) Install power steering pump.
(9) Connect fuel supply line quick connect fitting.
(10) Connect the vacuum lines at the throttle body
and intake manifold.
(11) Connect engine harness at the following
points (Fig. 46) :
²Intake Air Temperature (IAT) Sensor
²Idle Air Control (IAC) Motor
²Fuel Injectors
²Throttle Position (TPS) Switch
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold Absolute Pressure (MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
(12) Position and install heater hoses and tubes
onto intake manifold.
(13) Install the heater hoses onto the heater core
and the engine front cover.
(14) Install generator.
(15) Install A/C condenser, radiator and transmis-
sion oil cooler as an assembly.
(16) Connect radiator upper and lower hoses.
(17) Connect the transmission oil cooler lines to
the radiator.
(18) Install accessory drive belt, fan assembly and
shroud.
(19) Install A/C compressor. Tighten the A/C com-
pressor and generator M10 mounting bolts 40±68N´M
(30±50 ft. lbs.) and the M8 bolts 22±34 N´m (200±300
in. lbs.).
Fig. 43 Crankshaft Position Sensor
1 ± CRANKSHAFT POSITION SENSOR
2 ± CYLINDER HEAD COVER
3 ± CAMSHAFT POSITION SENSOR
4 ± RIGHT SIDE CYLINDER BLOCK
Fig. 44 Crankcase Breather Connection Points
1 ± CRANKCASE BREATHERS
Fig. 45 Heater Hoses and Tubes Removal /
Installation
1 ± HEATER HOSES AND TUBES
2 ± ROUTING/RETAINING CLIPS
DN4.7L ENGINE 9 - 33
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (20) Install both breathers. Connect tube to both
crankcase breathers (Fig. 44).
(21) Connect throttle and speed control cables.
(22) Install throttle body resonator assembly and
air inlet hose. Tighten clamps 4 N´m (35 in. lbs.).
(23) Raise vehicle.
(24) Install transmission to engine mounting bolts.
Tighten the bolts to 41 N´m (30 ft. lbs.).
(25) Install torque converter bolts (Automatic
Transmission Only).
(26) Connect crankshaft position sensor (Fig. 43).
(27)4X4 vehiclesPosition and install the axle
isolator bracket onto the axle, transmission and
engine block. Tighten bolts to specification. Refer to
Specifications in this section.
(28) Install starter.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.(29) Install structural cover. Refer to Structural
Cover in this section.
(30) Install exhaust crossover pipe.
(31) Install engine block heater power cable, If
equipped.
(32)4X4 vehiclesConnect axle vent tube to left
side engine mount.
(33) Lower vehicle.
(34) Check and fill engine oil.
(35) Recharge the A/C system.
(36) Refill the engine cooling system. Refer to
COOLING SYSTEM.
(37) Install the battery tray and battery.
(38) Connect the battery positive and negative
cables.
(39) Start the engine and check for leaks.
Fig. 46 Throttle Body Connection Points
1 ± THROTTLE BODY
2 ± TPS
3 ± IAC MOTOR
4 ± IAT SENSOR
5 ± MOUNTING SCREWS
Fig. 47 Engine Lifting Fixture Attachment Locations
1 ± ATTACHING LOCATION
2 ± ADJUSTABLE HOOK
3 ± SPECIAL TOOL 8347 ENGINE LIFT FIXTURE
4 ± ATTACHING LOCATIONS
9 - 34 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

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)