lock DODGE DURANGO 2000 1.G User Guide

Downloaded from www.Manualslib.com manuals search engine (6) Identify the fluid in the cylinders (i.e. coolant,
fuel, oil, etc.).
(7) Make sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt engine oil into the cylinders to lubricate
the walls. This will prevent damage on restart.
(10) Install new spark plugs.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil.
(15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.
VALVE SERVICE
REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
NOTE: When refacing valves and valve seats, it is
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Using a suitable dial indicator measure the
center of the valve seat Total run out must not
exceed 0.051 mm (0.002 in).
(2) Apply a small amount of Prussian blue to the
valve seat, insert the valve into the cylinder head,
while applying light pressure on the valve rotate the
valve. Remove the valve and examine the valve face.
If the blue is transferred below the top edge of the
valve face, lower the valve seat using a 15 degree
stone. If the blue is transferred to the bottom edge of
the valve face, raise the valve seat using a 65 degree
stone.
(3) When the seat is properly positioned the width
of the intake seat must be 1.75 ± 2.36 mm (0.0689 ±
0.0928 in.) and the exhaust seat must be 1.71 ± 2.32
mm (0.0673 ± 0.0911 in.).
(4) Check the valve spring installed height after
refacing the valve and seat. The installed height for
both intake and exhaust valve springs must not
exceed 41.44 mm (1.6315 in.).
(5) The valve seat and valve face must maintain a
face angle of 44.5 ± 45 degrees angle.
ENGINE TIMINGÐVERIFICATION
CAUTION: The 4.7L is a non free-wheeling design
engine. Therefore, correct engine timing is critical.
NOTE: Components referred to as left hand or right
hand are as viewed from the drivers position inside
the vehicle.
NOTE: The blue link plates on the chains and the
dots on the camshaft drive sprockets may not line
up during the timing verification procedure. The
blue link plates are lined up with the sprocket dots
only when re-timing the complete timing drive.
Once the timing drive is rotated blue link-to-dot
alignment is no longer valid.
Engine base timing can be verified by the following
procedure:
(1) Remove the cylinder head covers. Refer to the
procedure in this section.
(2) Using a mirror, locate the TDC arrow on the
front cover (Fig. 11). Rotate the crankshaft until the
mark on the crankshaft damper is aligned with the
TDC arrow on the front cover. The engine is now at
TDC.
Fig. 10 Valve Assembly Configuration
1 ± VALVE LOCKS (3±BEAD)
2 ± RETAINER
3 ± VALVE STEM OIL SEAL
4 ± INTAKE VALVE
5 ± EXHAUST VALVE
6 ± VALVE SPRING
DN4.7L ENGINE 9 - 19
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine (3) Note the location of the V8 mark stamped into
the camshaft drive gears (Fig. 12). If the V8 mark on
each camshaft drive gear is at the twelve o'clock posi-
tion, the engine is at TDC on the exhaust stroke. If
the V8 mark on each gear is at the six o'clock posi-
tion, the engine is at TDC on the compression stroke.
(4) If both of the camshaft drive gears are off in
the same or opposite directions, the primary chain or
both secondary chains are at fault. Refer to Timing
Chain and Sprockets procedure in this section.
(5) If only one of the camshaft drive gears is off
and the other is correct, the problem is confined to
one secondary chain. Refer to Single camshaft tim-
ing, in this procedure.
(6) If both camshaft drive gear V8 marks are at
the twelve o'clock or the six o' clock position the
engine base timing is correct. Reinstall the cylinder
head covers.
SINGLE CAMSHAFT TIMING
NOTE: to adjust the timing on one camshaft, pre-
form the following procedure.
(1) Using Chain Tensioner Wedge, special tool
8350, stabilize the secondary chain drive. For refer-
ence purposes, mark the chain-to-sprocket position
(Fig. 13).
(2) Remove the camshaft drive gear retaining bolt.
(3) Carefully remove the camshaft drive gear from
the camshaft.
(4) Re-index the camshaft drive gear in the chain
until the V8 mark is at the same position as the V8
mark on the opposite camshaft drive gear.
NOTE: When gripping the camshaft, place the pli-
ers on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.
(5) Using a suitable pair of adjustable pliers,
rotate the camshaft until the alignment dowel on the
camshaft is aligned with the slot in the camshaft
drive gear (Fig. 14).
CAUTION: Remove excess oil from camshaft
sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.
(6) Position the camshaft drive gear onto the cam-
shaft, remove oil from bolt then install the retaining
bolt. Using Special Tools, Spanner Wrench 6958 with
Adapter Pins 8346 and a suitable torque wrench,
Tighten retaining bolt to 122N´m (90 ft. Lbs.) (Fig.
15) (Fig. 16).
(7) Remove special tool 8350.
(8) Rotate the crankshaft two full revolutions, then
reverify that the camshaft drive gear V8 marks are
in fact aligned.
(9) Install the cylinder head covers. Refer to Cylin-
der Head Cover in this section.
Fig. 11 Engine Top Dead Center (TDC) Indicator
Mark
1 ± TIMING CHAIN COVER
2 ± CRANKSHAFT TIMING MARKS
9 - 20 4.7L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine TIMING CHAINÐMEASURING WEAR
NOTE: This procedure must be performed with the
timing chain cover removed.
(1) Remove the timing chain cover. Refer to Timing
Chain Cover in this section for procedure.
(2) To determine if the secondary timing chains
are worn, rotate the engine clockwise until maximum
tensioner piston extension is obtained. Measure the
distance between the secondary timing chain ten-
sioner housing and the step ledge on the piston (Fig.
17). The measurement at point (A) must be less than
15mm (.5906 inches).
(3) If the measurement exceeds the specification
the secondary timing chains are worn and require
replacement. Refer to Timing Chain and Sprockets in
this section for procedure.
PISTONSÐFITTING
BORE GAGE METHOD
(1) To correctly select the proper size piston, a cyl-
inder bore gauge, capable of reading in 0.003 mm
(.0001 in.) INCREMENTS is required. If a bore
gauge is not available, do not use an inside microme-
ter.
(2) Measure the inside diameter of the cylinder
bore at a point 49.5 mm (1-15/16 inches) below top of
bore. Start perpendicular (across or at 90 degrees) to
the axis of the crankshaft at point A and then takean additional bore reading 90 degrees to that at point
B (Fig. 19).
(3) The coated pistons will be serviced with the
piston pin and connecting rod pre-assembled. Tin
coated pistons should not be used as replacements for
coated pistons.
(4) The coating material is applied to the piston
after the final piston machining process. Measuring
the outside diameter of a coated piston will not pro-
vide accurate results (Fig. 18). Therefore measuring
the inside diameter of the cylinder bore with a dial
Bore Gauge isMANDATORY. To correctly select the
proper size piston, a cylinder bore gauge capable of
reading in 0.003 mm (.0001 in.) increments is
required.
(5) Piston installation into the cylinder bore
requires slightly more pressure than that required
for non-coated pistons. The bonded coating on the
piston will give the appearance of a line-to-line fit
with the cylinder bore.
Fig. 14 Camshaft Dowel To Sprocket Alignment
1 ± ADJUSTABLE PLIERS
2 ± CAMSHAFT DOWEL
Fig. 15 Camshaft Sprocket InstallationÐLeft
Cylinder Head
1 ± TORQUE WRENCH
2 ± CAMSHAFT SPROCKET
3 ± LEFT CYLINDER HEAD
4 ± SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
9 - 22 4.7L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine PISTON RINGSÐFITTING
RING END GAP
Before reinstalling used rings or installing new
rings, the ring clearances must be checked.
(1) Wipe the cylinder bore clean.
(2) Insert the ring in the cylinder bore.
NOTE: The ring gap measurement must be made
with the ring positioned at least 12mm (0.50 inch.)
from bottom of cylinder bore.
(3) Using a piston, to ensure that the ring is
squared in the cylinder bore, slide the ring downward
into the cylinder.
(4) Using a feeler gauge check the ring end gap
(Fig. 20). Replace any rings not within specification.
PISTON RING SIDE CLEARANCE
NOTE: Make sure the piston ring grooves are clean
and free of nicks and burrs.
(5) Measure the ring side clearance as shown (Fig.
21) make sure the feeler gauge fits snugly between
the ring land and the ring. Replace any ring not
within specification.
(6) Rotate the ring around the piston, the ring
must rotate in the groove with out binding.
EARLY BUILD
(7) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Ensure No. 2 ring is installed with
manufacturers I.D. mark (Dot) facing up, towards top
of the piston.
LATE BUILD
The No. 1 and No. 2 piston rings have a different
cross section. Ensure No. 2 ring is installed with
manufacturers I.D. mark (Dot) facing up, towards top
of the piston. On late build engines the piston top
ring groove and crown are not anodized therefore,
the No. 1 piston ring is coated with an anti-friction
coating. Care must be used to ensure that wheninstalling piston rings on late build engines that the
correct No. 1 piston ring be installed, failure to use
the correct piston ring can cause severe damage to
the piston and/or cylinder block.
Fig. 20 Ring End Gap MeasurementÐTypical
1 ± FEELER GAUGE
Fig. 21 Measuring Piston Ring Side Clearance
1 ± FEELER GAUGE
PISTON RING SPECIFICATION CHART
Ring Position Groove Maximum
Clearance Clearance
Upper Ring .051-.094mm 0.11mm
(0.0020-.0037
in.)(0.004 in.)
Intermediate
Ring0.04-0.08mm 0.10mm
(0.0016-0.0031
in.)(0.004 in.)
Oil Control Ring .019-.229mm .25mm
(Steel Rails) (.0007-.0090 in.) (0.010 in.)
Ring Position Ring Gap Wear Limit
Upper Ring 0.20-0.36mm 0.40mm
(0.008-0.014 in.) (0.0016in.)
Intermediate
Ring0.37-0.63mm 0.71mm
(0.014-0.025 in.) (0.028in.)
Oil Control Ring 0.025-0.76mm 1.52mm
(Steel Rail) (0.010- 0.030
in.)(0.060in.)
9 - 24 4.7L ENGINEDN
SERVICE PROCEDURES (Continued)
2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99 December, 1999

Downloaded from www.Manualslib.com manuals search engine (5) Install bearing cap and connecting rod on the
journal and tighten bolts to 27 N´m (20 ft. lbs.) plus a
90É turn. DO NOT rotate crankshaft. Plastigage will
smear, resulting in inaccurate indication.
(6) Remove the bearing cap and determine amount
of bearing-to-journal clearance by measuring the
width of compressed Plastigage (Fig. 29). Refer to
Engine Specifications for the proper clearance.Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(7) If the correct clearance is indicated, replace-
ment of the bearing inserts is not necessary. Remove
the Plastigage from crankshaft journal and bearing
insert. Proceed with installation.
(8) If bearing-to-journal clearance exceeds the
specification, determin which services bearing set to
use the bearing sizes are as follows:
Fig. 25 Connecting Rod Bearing Inspection
1 ± UPPER BEARING HALF
2 ± MATING EDGES
3 ± GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 ± WEAR PATTERN Ð ALWAYS GREATER ON UPPER
BEARING
5 ± LOWER BEARING HALF
Fig. 26 Locking Tab Inspection
1 ± ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 27 Scoring Caused by Insufficient Lubrication
or by Damaged Crankshaft Pin Journal
Fig. 28 Piston and Connecting RodÐInstallation
1 ± ªFº TOWARD FRONT OF ENGINE
2 ± OIL SLINGER SLOT
3 ± RING COMPRESSOR
4 ± SPECIAL TOOL 8507
9 - 26 4.7L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine (9) Repeat the Plastigage measurement to verify
your bearing selection prior to final assembly.
(10) Once you have selected the proper insert,
install the insert and cap. Tighten the connecting rod
bolts to 27 N´m (20 ft. lbs.) plus a 90É turn.
Slide snug-fitting feeler gauge between the con-
necting rod and crankshaft journal flange (Fig. 30).
Refer to Engine Specifications for the proper clear-
ance. Replace the connecting rod if the side clearance
is not within specification.
CRANKSHAFT MAIN BEARINGS
INSPECTION
Wipe the inserts clean and inspect for abnormal
wear patterns and for metal or other foreign material
imbedded in the lining. Normal main bearing insert
wear patterns are illustrated (Fig. 31).
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.Inspect the back of the inserts for fractures, scrap-
ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage.
Replace all damaged or worn bearing inserts.
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cylinder block.
Refer to Crankshaft in this section for procedure.
Clean the oil off the main bearing journal.
Determine the maximum diameter of the journal
with a micrometer. Measure at two locations 90É
apart at each end of the journal.
The maximum allowable taper is 0.008mm (0.0004
inch.) and maximum out of round is 0.005mm (0.002
inch). Compare the measured diameter with the jour-
Fig. 29 Measuring Bearing Clearance with
Plastigage
1 ± PLASTIGAGE SCALE
2 ± COMPRESSED PLASTIGAGE
Bearing
MarkSIZE USED WITH
JOURNAL SIZE
.025 US.025 mm 50.983-50.967 mm
(.001 in.) (2.0073-2.0066 in.)
Std.STANDARD 50.992-51.008 mm
(2.0076-2.0082 in.)
.250 US.250 mm 50.758-50.742 mm
(.010 in.) (1.9984-1.9978 in.)
Fig. 30 Checking Connecting Rod Side ClearanceÐ
Typical
Fig. 31 Main Bearing Wear Patterns
1 ± UPPER INSERT
2 ± NO WEAR IN THIS AREA
3 ± LOW AREA IN BEARING LINING
4 ± LOWER INSERT
DN4.7L ENGINE 9 - 27
SERVICE PROCEDURES (Continued)

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 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)