fuel injector 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 (10) Position and install heater hoses and tubes
onto intake manifold.
(11) Install the heater hoses to the heater core and
engine front cover.(12) Connect electrical connectors for the following
components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
²Ignition coil towers
²Fuel injectors
(13) Install top oil dipstick tube retaining bolt and
ground strap.
(14) Connect generator electrical connections.
(15) Connect Vapor purge hose, Brake booster
hose, Speed control servo hose, Positive crankcase
ventilation (PCV) hose.
(16) Fill cooling system.
(17) Install resonator assembly and air inlet hose.
(18) Connect negative cable to battery.
EXHAUST MANIFOLDS
RIGHT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable for battery.
(2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
(3) Remove accessory drive belt. Refer to COOL-
ING SYSTEM.
(4) Remove A/C compressor from mounting and set
aside.
(5) Remove A/C accumulator support bracket fas-
tener.
(6) Drain coolant below heater hose level. Refer to
COOLING SYSTEM.
(7) Remove heater hoses at engine.
(8) Remove fasteners attaching exhaust manifold
heat shield.
(9) Remove heat shield.
(10) Remove upper exhaust manifold attaching fas-
teners.
(11) Raise vehicle on hoist.
(12) Disconnect exhaust pipe from manifold.
(13) Remove fasteners attaching starter. Move
starter aside.
(14) Remove lower exhaust manifold attaching fas-
teners.
(15) Remove exhaust manifold and gasket (Fig.
52). Manifold is removed from below the engine com-
partment.
Fig. 50 Heater Hoses and Tubes Removal /
Installation
1 ± HEATER HOSES AND TUBES
2 ± ROUTING/RETAINING CLIPS
Fig. 51 Intake Manifold Tightening Sequence
9 - 36 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

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)

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
DN5.9L ENGINE 9 - 139
DESCRIPTION AND OPERATION (Continued)

Downloaded from www.Manualslib.com manuals search engine SERVICE DIAGNOSISÐGASOLINE ENGINES
PERFORMANCE DIAGNOSIS CHARTÐGASOLINE ENGINES
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL
NOT CRANK1. Weak or dead battery 1. Charge/Replace Battery. Refer to Group 8A,
Battery, for correct procedures. Check charging
system. Refer to Group 8C, Charging Systems, for
correct procedures.
2. Corroded or loose battery
connections2. Clean/tighten suspect battery/starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. Refer to Group 8B,
Starting Systems, for correct diagnostics/procedures
4. Seized accessory drive
component4. Remove accessory drive belt and attempt to start
engine. If engine starts, repair/replace seized
component.
5. Engine internal mechanical
failure or hydro-static lock5. Refer to Group 9, Engine, for correct diagnostics/
procedures
ENGINE CRANKS
BUT WILL NOT
START1. No spark 1. Check for spark. Refer to Group 8D, Ignition
System, for correct procedures.
2. No fuel 2. Perform fuel pressure test, and if necessary,
inspect fuel injector(s) and driver circuits. Refer to
Group 14, Fuel System, for correct procedures.
3. Low or no engine compression 3. Perform cylinder compression pressure test. Refer
to Group 9, Engine, for correct procedures.
ENGINE LOSS OF
POWER1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor (Refer to Group 8D,
Ignition System
3. Worn or incorrect gapped spark
plugs3. Clean plugs and set gap. (Refer to Group 8D,
Ignition System)
4. Dirt or water in fuel system 4. Clean system and replace fuel filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression
9. Burned, warped, or pitted valves 9. Install/Reface valves as necessary
10. Plugged or restricted exhaust
system10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted cables
12. Faulty ignition coil 12. Test and replace, as necessary (Refer to Group
8D, Ignition System)
ENGINE STALLS
OR ROUGH IDLE1. Carbon build-up on throttle plate 1. Remove throttle body and de-carbon. (Refer to
Group 14 for correct procedures)
2. Engine idle speed too low 2. Check Idle Air Control circuit. (Refer to Group 14,
Fuel System)
9 - 142 5.9L ENGINEDN
DIAGNOSIS AND TESTING (Continued)