Cooler DODGE DURANGO 1999 1.G Workshop Manual

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 (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 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)

Downloaded from www.Manualslib.com manuals search engine (2) Remove accessory drive belt refer to Group 7,
Cooling System for procedure.
(3) Remove A/C compressor mouning fasteners and
set aside.(4) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(5) Remove upper radiator hose.
(6) Using Special Tools 6958 Spanner with Adapter
Pins 8346 loosen fan and viscous assembly from
water pump (Fig. 126).
(7) Remove fan and viscous assembly.
(8) Disconnect electrical connector for fan mounted
inside radiator shroud.
(9) Remove radiator shroud attaching fasteners.
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
(10) Remove radiator shroud.
(11) Remove crankshaft damper bolt.
(12) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 127).
(13) Using Special Tool 8511, remove crankshaft
front seal (Fig. 128).
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) Using Special Tool 8348 and 8512, install
crankshaft front seal (Fig. 129).
Fig. 124 Oil Pump and Primary Timing Chain
Tightening Sequence
Fig. 125 Oil Pressure Sending Unit
1 ± BELT
2 ± OIL PRESSURE SENSOR
3 ± OIL FILTER
4 ± ELEC. CONNECTOR
Fig. 126 Fan AssemblyÐRemoval/Installation
1 ± SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2±FAN
DN4.7L ENGINE 9 - 71
REMOVAL AND INSTALLATION (Continued)