Shaft DODGE DURANGO 2000 1.G Manual Online

Downloaded from www.Manualslib.com manuals search engine (13) Install distributor and distributor drive shaft.
(14) Install push rods and tappets.
(15) Install rocker arms.
(16) Install timing case cover.
(17) Install cylinder head covers.
(18) Install intake manifold.
(19) Install the engine cover.
(20) Install the A/C Condenser (if equipped).
(21) Install the radiator. Refer to Group 7, Cooling
for the correct procedures.
(22) Refill cooling system. Refer to Group 7, Cool-
ing for the correct procedures.
(23) Start engine check for leaks.
CAMSHAFT BEARINGS
REMOVAL
NOTE: This procedure requires that the engine is
removed from the vehicle.
(1) With engine completely disassembled, drive out
rear cam bearing core plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell. Drive
out bearing shells (Fig. 57).
INSTALLATION
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter.
(2) Position rear bearing in the tool. Install horse-
shoe lock and by reversing removal procedure, care-
fully drive bearing shell into place.
(3) Install remaining bearings in the same man-
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft.Be sure this plug does not leak.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 58).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig. 56 Alignment of Timing Marks
1 ± TIMING MARKSFig. 57 Camshaft Bearings Removal/Installation with
Tool C-3132-A
1 ± SPECIAL TOOL C-3132±A
2 ± MAIN BEARING OIL HOLE
Fig. 58 Upper Main Bearing Removal and
Installation with Tool C-3059
1 ± SPECIAL TOOL C-3059
2 ± BEARING
3 ± SPECIAL TOOL C-3059
4 ± BEARING
DN5.2L ENGINE 9 - 113
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight-
ened. All bearing capbolts removed during service pro-
cedures are to be cleaned and oiled before installation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 58).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Tool C-3059.
(3)
Install the bearing caps. Clean and oil the bolts.
Tighten the capbolts to 115 N´m (85 ft. lbs.) torque.
(4) Install the oil pump.
(5) Install the oil pan.
(6) Start engine check for leaks.
DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
(1) Remove distributor, refer to Group 8D, Ignition
Systems for the proper procedure.
(2) Remove the intake manifold. Refer to Intake
Manifold in this section for correct procedure.
(3) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and thread down until a
tight fit is obtained (Fig. 59).
(4) Hold puller screw and tighten puller nut until
bushing is removed.
INSTALLATION
(1) Slide new bushing over burnishing end of Dis-
tributor Drive Shaft Bushing Driver/Burnisher Tool
C-3053. Insert the tool and bushing into the bore.
(2) Drive bushing and tool into position, using a
hammer (Fig. 60).
(3) As the burnisher is pulled through the bushing,
the bushing is expanded tight in the block and bur-
nished to correct size (Fig. 61).DO NOT ream this
bushing.CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
occur.
(4) Install the intake manifold.
DISTRIBUTOR INSTALLATION
NOTE: Before installing the distributor, the oil
pump drive shaft must be aligned to number one
cylinder.
(1) Rotate crankshaft until No.1 cylinder is at top
dead center on the firing stroke.
(2) When in this position, the timing mark of
vibration damper should be under ª0º on the timing
indicator.
(3) Install the shaft so that after the gear spirals
into place, it will index with the oil pump shaft. The
slot on top of oil pump shaft should be aligned
towards the left front intake manifold attaching bolt
hole (Fig. 62).
(4) Install distributor, refer to Group 8D, Ignition
Systems for the proper procedure.
Fig. 59 Distributor Driveshaft Bushing Removal
1 ± SPECIAL TOOL C-3052
2 ± BUSHING
Fig. 60 Distributor Driveshaft Bushing Installation
1 ± SPECIAL TOOL C-3053
2 ± BUSHING
Fig. 61 Burnishing Distributor Driveshaft Bushing
1 ± SPECIAL TOOL C-3053
2 ± BUSHING
9 - 114 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine After the distributor has been installed, its rota-
tional position must be set using theSET SYNC
mode of the DRB scan tool. Refer to Checking Dis-
tributor Position following the Distributor Installa-
tion section in Group 8D, Ignition system.
Do not attempt to adjust ignition timing by
rotating the distributor. It has no effect on igni-
tion timing. Adjusting distributor position will
effect fuel synchronization only.
OIL PAN
REMOVAL
2WD
(1) Disconnect the negative cable from the battery.
(2) Remove air cleaner assembly.
(3) Remove engine oil dipstick.
(4) Disconnect distributor cap and position away
from cowl.
(5) Remove the fan shroud. Refer to COOLING
SYSTEM.
(6) Disconnect throttle valve cable from throttle
body and mounting bracket (Fig. 62A).
(7) Raise vehicle.
(8) Drain engine oil.
(9) Remove exhaust pipe from exhaust manifolds.
(10) Remove engine mount insulator through bolts.
(11) Raise engine by way of oil pan using a block
of wood between the jack and oil pan.
(12) When engine is high enough, place mount
through bolts in the engine mount attaching points
on the frame brackets.
(13) Lower engine so bottom of engine mounts rest
on the replacement bolts placed in the engine mount
frame brackets.
(14) Remove transmission to engine braces.
(15) Remove starter. Refer to STARTING SYS-
TEMS.(16) Remove transmission torque converter inspec-
tion cover.
(17) Disconnect rear support cushion from cross-
member.
(18) Raise rear of transmission away from cross-
member.
(19) Remove oil pan and one-piece gasket.
4WD
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove front driving axle. Refer to DIFFER-
ENTIAL and DRIVELINE.
(6) Remove both engine mount support brackets.
(7) Remove transmission torque converter inspec-
tion cover.
(8) Remove oil pan and one-piece gasket.
INSTALLATION
2WD
(1) Fabricate 4 alignment dowels from 5/16x11/2
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier
installation and removal with a screwdriver (Fig. 63).
Fig. 62 Position of Oil Pump Shaft Slot
1 ± DISTRIBUTOR DRIVE
Fig. 62A Throttle Valve Cable Removal/Installation
1 ± TRANSMISSION THROTTLE VALVE CABLE BRACKET
2 ± AIR INLET DUCT
3 ± TRANSMISSION THROTTLE VALVE CABLE
DN5.2L ENGINE 9 - 115
REMOVAL AND INSTALLATION (Continued)
2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99 December, 1999

Downloaded from www.Manualslib.com manuals search engine PISTON AND CONNECTING ROD ASSEMBLY
REMOVAL
(1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.
(4) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block. Be sure to keep tops of pistons covered
during this operation.
(5) Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and
connecting rod assemblies, rotate crankshaft to cen-
ter the connecting rod in the cylinder bore and at
BDC.Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mat-
ing rod.
INSTALLATION
(1) Be sure that compression ring gaps are stag-
gered so that neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 65).
(3) Immerse the piston head and rings in clean
engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385).Be sure position of rings
does not change during this operation.(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con-
necting rod cap and cylinder bore number are the
same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 N´m (45 ft. lbs.) torque.
(9) Install the oil pan.
(10) Install the cylinder head.
(11) Install the engine into the vehicle.CRANKSHAFT
REMOVAL
NOTE: This procedure can be done in vehicle.
However the transmission must be removed first.
(1) If crankshaft is to be removed while engine is
in vehicle remove the transmission. Refer to Group
21, for correct procedure.
(2) Remove the oil pan.
(3) Remove the oil pump from the rear main bear-
ing cap.
(4) Remove the vibration damper.
(5) Remove the timing chain cover.
(6) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.
CAUTION: Support crankshaft before removing
main bearing caps. failure to do so will allow the
crankshaft to fall damaging the crankshaft.
(7) Using a suitable jack, support the crankshaft.
(8) Identify main bearing caps before removal.
Remove main bearing caps and bearings one at a
time.
(9) Lower the crankshaft out of the block.
(10) Remove and discard the crankshaft rear oil
seals.
(11) Remove and discard the front crankshaft oil
seal.
Fig. 65 Proper Ring Installation
1 ± OIL RING SPACER GAP
2 ± SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 ± OIL RING RAIL GAP (BOTTOM)
4 ± TOP COMPRESSION RING GAP
9 - 116 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
(1) Clean Gasket Maker residue and sealant from
the cylinder block and rear cap mating surface. Do
this before applying the MopartGasket Maker and
the installation of rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of MopartGasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 66). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.
(8) To align the bearing cap, use cap slot, align-
ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 N´m (85 ft. lbs.) torque.
(10) Install oil pump.
(11) Install the timing chain cover.
(12) Install the vibration damper.
(13) Position the connecting rods onto the crank-
shaft and install the rod bearing caps. Tighten the
nuts to 61 N´m (45 ft. lbs.).
(14) Apply MopartSilicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 67).Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(15) Install new front crankshaft oil seal.
(16) Immediately install the oil pan.
(17) If the transmission was removed, install the
transmission.
OIL PUMP
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from rear main bearing
cap.
INSTALLATION
(1) Install oil pump. During installation slowly
rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold the oil pump base flush against mating
surface on No.5 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
N´m (30 ft. lbs.) torque.
(3) Install the oil pan.
CRANKSHAFT OIL SEALÐFRONT
The oil seal can be replaced without removing the
timing chain cover provided the cover is not mis-
aligned.
(1) Disconnect the negative cable from the battery.
(2) Remove vibration damper.
(3) If front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa-
tion/alignment tool 6635, should fit with minimum
Fig. 66 Sealant Application to Bearing Cap
1 ± .25 DROP OF LOCTITE 515 ON BOTH SIDES OF REAR
MAIN CAP
Fig. 67 Apply Sealant to Bearing Cap to Block Joint
1 ± MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE
TIP
2 ± SEALANT APPLIED
3 ± CYLINDER BLOCK
4 ± REAR MAIN BEARING CAP
DN5.2L ENGINE 9 - 117
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine interference. If tool does not fit, the cover must be
removed and installed properly.
(4) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal bore of cover.
(5) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 68). Seat
the oil seal in the groove of the tool.
(6) Position the seal and tool onto the crankshaft
(Fig. 69).
(7) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 70).
(8) Remove the vibration damper bolt and seal
installation tool.
(9) Inspect the seal flange on the vibration
damper.
(10) Install the vibration damper.
(11) Connect the negative cable to the battery.
CRANKSHAFT OIL SEALSÐREAR
The service seal is a 2 piece, viton seal. The upper
seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
The lower seal half can only be installed with the
rear main bearing cap removed.
UPPER SEAL ÐCRANKSHAFT REMOVED
REMOVAL
(1) Remove the crankshaft. Discard the old upper
seal.
INSTALLATION
(1) Clean the cylinder block rear cap mating sur-
face. Make sure the seal groove is free of debris.
Fig. 68 Placing Oil Seal on Installation Tool 6635
1 ± CRANKSHAFT FRONT OIL SEAL
2 ± INSTALL THIS END INTO SPECIAL TOOL 6635
Fig. 69 Position Tool and Seal onto Crankshaft
1 ± SPECIAL TOOL 6635
2 ± OIL SEAL
3 ± TIMING CHAIN COVER
Fig. 70 Installing Oil Seal
1 ± SPECIAL TOOL 6635
2 ± TIMING CHAIN COVER
9 - 118 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of MopartGasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 71). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.
(8) To align the bearing cap, use cap slot, align-
ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 N´m (85 ft. lbs.) torque.
(10) Install oil pump.
(11) Apply MopartSilicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 72).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(12) Install new front crankshaft oil seal.
(13) Immediately install the oil pan.
UPPER SEAL ÐCRANKSHAFT INSTALLED
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal.
(4) Carefully remove and discard the old upper oil
seal.
INSTALLATION
(1) Clean the cylinder block mating surfaces before
oil seal installation. Check for burr at the oil hole on
the cylinder block mating surface to rear cap.
(2) Lightly oil the new upper seal lips with engine
oil. To allow ease of installation of the seal, loosen at
least the 2 main bearing caps forward of the rear
bearing cap.
(3) Rotate the new upper seal into the cylinder
block being careful not to shave or cut the outer sur-
face of the seal. To assure proper installation, use the
installation tool provided with the kit. Install the
new seal with the white paint facing towards the
rear of the engine.
(4) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(5) Apply 5 mm (0.20 in) drop of MopartGasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 71). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application. Be sure the white paint faces
toward the rear of the engine.
Fig. 71 Sealant Application to Bearing Cap
1 ± MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS
2 ± LOCTITE 518 (OR EQUIVALENT)
3 ± CAP ALIGNMENT SLOT
4 ± REAR MAIN BEARING CAP
Fig. 72 Apply Sealant to Bearing Cap to Block Joint
1 ± MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE
TIP
2 ± SEALANT APPLIED
3 ± CYLINDER BLOCK
4 ± REAR MAIN BEARING CAP
DN5.2L ENGINE 9 - 119
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (6) To align the bearing cap, use cap slot, align-
ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(7) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten ALL cap bolts
to 115 N´m (85 ft. lbs.) torque.
(8) Install oil pump.
(9) Apply MopartSilicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 72).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(10) Immediately install the oil pan.
LOWER SEAL
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Remove the rear main bearing cap and discard
the old lower seal.
INSTALLATION
(1) Clean the rear main cap mating surfaces
including the oil pan gasket groove.
(2) Carefully install a new upper seal (refer to
Upper Seal Replacement - Crankshaft Installed pro-
cedure above).
(3) Lightly oil the new lower seal lips with engine
oil.
(4) Install a new lower seal in bearing cap with
the white paint facing the rear of engine.
(5) Apply 5 mm (0.20 in) drop of MopartGasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 71). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.
(6) To align the bearing cap, use cap slot, align-
ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(7) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten the cap bolts
to 115 N´m (85 ft. lbs.) torque.
(8) Install oil pump.
(9) Apply MopartSilicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 72).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(10) Immediately install the oil pan.
ENGINE CORE OIL AND CAMSHAFT PLUGS
Engine core plugs have been pressed into the oil
galleries behind the camshaft thrust plate (Fig. 73).
This will reduce internal leakage and help maintain
higher oil pressure at idle.
REMOVAL
(1) Using a blunt tool such as a drift or a screw-
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 74).
(2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig.
74).
INSTALLATION
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Be certain the new plug is cleaned of all oil or
grease.
(1) Coat edges of plug and core hole with Mopart
Gasket Maker, or equivalent.
CAUTION: DO NOT drive cup plug into the casting,
as restricted coolant flow can result and cause seri-
ous engine problems.
(2) Using proper plug drive, drive cup plug into
hole. The sharp edge of the plug should be at least
0.50 mm (0.020 in.) inside the lead-in chamfer.
(3) It is not necessary to wait for curing of the
sealant. The cooling system can be filled and the
vehicle placed in service immediately.
Fig. 73 Location of Cup Plugs in Oil Galleries
1 ± CUP PLUGS
9 - 120 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading.
(3) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to the top edge of valve face, lower valve seat
with a 15É stone. If the blue is transferred to bottom
edge of valve face raise valve seat with a 60É stone.
(4) When seat is properly positioned the width of
intake seats should be 1.016-1.524 mm (0.040-0.060
inch). The width of the exhaust seats should be
1.524-2.032 mm (0.060-0.080 inch).
VALVE SPRING INSPECTION
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is 1-5/16 inch. Turn table of
Universals Valve Spring Tester Tool until surface is
in line with the 1-5/16 inch mark on the threaded
stud. Be sure the zero mark is to the front (Fig. 80).
Place spring over stud on the table and lift compress-
ing lever to set tone device. Pull on torque wrench
until ping is heard. Take reading on torque wrench
at this instant. Multiply this reading by 2. This will
give the spring load at test length. Fractional mea-
surements are indicated on the table for finer adjust-
ments. Refer to specifications to obtain specified
height and allowable tensions. Discard the springs
that do not meet specifications.
OIL PUMP
DISASSEMBLE
(1) Remove the relief valve as follows:
(a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and
insert a self-threading sheet metal screw.
(b) Clamp screw into a vise and while support-
ing oil pump, remove cap by tapping pump body
using a soft hammer. Discard retainer cap and
remove spring and relief valve (Fig. 81).
(2) Remove oil pump cover (Fig. 82).
(3) Remove pump outer rotor and inner rotor with
shaft (Fig. 82).
(4) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
ASSEMBLE
(1) Install pump rotors and shaft, using new parts
as required.
(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N´m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling
rotor cavity with engine oil.
Fig. 80 Testing Valve Spring for Compressed
Length
1 ± TORQUE WRENCH
2 ± VALVE SPRING TESTER
Fig. 81 Oil Pressure Relief Valve
1 ± OIL PUMP ASSEMBLY
2 ± COTTER PIN
3 ± RELIEF VALVE
4 ± RETAINER CAP
5 ± SPRING
DN5.2L ENGINE 9 - 123
DISASSEMBLY AND ASSEMBLY (Continued)

Downloaded from www.Manualslib.com manuals search engine CYLINDER BLOCK
DISASSEMBLE
With Engine removed from vehicle:
(1) Remove the cylinder heads. refer to Cylinder
Head in this section for correct procedure.
(2) Remove the exhaust manifolds. Refer to
Exhaust Manifolds in this section.
(3) Remove the oil pan. Refer to Oil Pan in this
section.
(4) Remove the piston and connecting rod assem-
blies. Refer to Piston and Connecting Rod in this sec-
tion.
(5) Remove the crankshaft. Refer to Crankshaft in
this section.
(6) Remove the core plugs.
ASSEMBLE
(1) Install the core plugs.
(2) Install the crankshaft.
(3) Install the piston and connecting rods.
(4) Install the oil pan.
(5) Install the cylinder heads.
(6) Install the exhaust manifolds.
(7) Install the intake manifold.
(8) Install the engine into the vehicle.
CLEANING AND INSPECTION
CYLINDER HEAD COVER
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
CYLINDER HEAD ASSEMBLY
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness
exceeds 0.00075 mm/mm (0.00075 inch/inch) times
the span length in inches in any direction, either
replace head or lightly machine the head surface.
FOR EXAMPLE:A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 X 0.00075 (12 X 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept-
able.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
PISTON AND CONNECTING ROD ASSEMBLY
INSPECTION
Check the crankshaft connecting rod journal for
excessive wear, taper and scoring.
Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
Check the pistons for taper and elliptical shape
before they are fitted into the cylinder bore (Fig. 83).
OIL PAN
CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove.DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
engine.
Fig. 82 Oil Pump
1 ± INNER ROTOR AND SHAFT
2 ± BODY
3 ± DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 ± COTTER PIN
5 ± RETAINER CAP
6 ± SPRING
7 ± RELIEF VALVE
8 ± LARGE CHAMFERED EDGE
9 ± BOLT
10 ± COVER
11 ± OUTER ROTOR
9 - 124 5.2L ENGINEDN
DISASSEMBLY AND ASSEMBLY (Continued)