ad blue DODGE DURANGO 2000 1.G Workshop Manual

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 (7) Rotate crankshaft until connecting rod journal
is on the center of cylinder bore. Insert rod and pis-
ton into cylinder bore and carefully position connect-
ing rod guides over crankshaft journal.
(8) Tap piston down in cylinder bore using a ham-
mer handle. While at the same time, guide connect-
ing rod into position on rod journal.
CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.
(9) Lubricate rod bolts and bearing surfaces with
engine oil. Install connecting rod cap and bearing.
Tighten bolts to 27 N´m (20 ft. lbs.) plus 90É.
(10) Install the following components: (Refer to
procedures in this section)
²Cylinder head(s).
²Timing chain and cover.
²Cylinder head covers.
²Oil pan and gasket/windage tray.
(11) Fill crankcase with proper engine oil to cor-
rect level.
(12) Connect negative cable to battery.
CRANKSHAFT
REMOVAL
NOTE: To remove the crankshaft from the engine,
the engine must be removed from the vehicle.
(1) Remove the engine. Refer to Engine Assembly
in this section for procedure.
(2) Remove the engine oil pump. Refer to Oil
Pump in this section for procedure.
CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.
(3) Remove oil pan bolts and oil pan.
(4) Remove the oil pump pickup tube and oil pan
gasket /windage tray.
(5) Remove the bedplate mounting bolts. Note the
location of the three stud bolts for installation.
(6) Remove the connecting rods from the crank-
shaft.
CAUTION: The bedplate to cylinder block mating
surface is a critical sealing surface. Do not pry on
or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear-
ing halves. Use care when handling bedplate as not
to drop or damage bearing halves. Installing main
bearing halves in the wrong position will cause
sever damage to the crankshaft.
NOTE: The bedplate has pry points cast into it. Use
these points only. The pry points are on both the
left and right sides, only the left side is shown.
(7) Carefully pry on the pry points (Fig. 117) to
loosen the bedplate then remove the bedplate.
CAUTION: When removing the crankshaft, use care
not to damage bearing surfaces on the crankshaft.
(8) Remove the crankshaft.
(9) Remove the crankshaft tone wheel.
INSPECTION
NOTE: Thoroughly inspect the connecting rod
bearing bores and main bearing bores for scoring,
blueing or severe scratches. Further disassembly
may be required.
Fig. 116 Piston and Connecting Rod Positioning
1 ± MAJOR THRUST SIDE OF PISTON
2 ± OIL SLINGER SLOT
DN4.7L ENGINE 9 - 67
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine If connecting rod bearing bores show damage, the
cylinder heads must be removed to service the piston
and rod assemblies. If the bedplate or the cylinder
block main bearing bores show damage the engine
must be replaced.
(1) If required, remove the main bearing halves
from the cylinder block and bedplate.
(2) Thoroughly clean the bedplate to cylinder block
sealing surfaces and main bearing bores. Remove all
oil and sealant residue.
(3) Inspect the bedplate main bearing bores for
cracks, scoring or severe blueing. If either condition
exists the engine must be replaced.
(4) Inspect the crankshaft thrust washer for scor-
ing, scratches or blueing. If either condition exist
replace the thrust washer.
(5) Inspect the oil pan gasket/windage tray for
splits, tears or cracks in the gasket sealing surfaces.
Replace gasket as necessary.
INSTALLATION
CAUTION: Main bearings are select fit. Refer to
Crankshaft Main Bearings in this section for proper
bearing selections.(1) Lubricate upper main bearing halves with
clean engine oil.
CAUTION: When installing crankshaft, use care not
to damage bearing surfaces on the crankshaft.
NOTE: Apply sealant to the tone wheel retaining
screws prior to installation.
(2) Install the crankshaft tone wheel. torque the
mounting screws to 22 N´m (21 ft. lbs.).
(3) Install the thrust washer (Fig. 118).
(4) Position crankshaft in cylinder block.
CAUTION: The bedplate to cylinder block mateing
surface must be coated with sealant prior to instal-
lation. Failure to do so will cause severe oil leaks.
NOTE: The installation time to install the bedplate
after the sealant has been applied is critical.
NOTE: Make sure that the bedplate and cylinder
block sealing surfaces are clean and free of oil or
other contaminants. Contaminants on the sealing
surfaces may cause main bearing distortion and/or
oil leaks.
(5) Apply a 2.5mm (0.100 inch) (Fig. 119) bead of
MopartGen II Silicone Rubber Adhesive sealant to
the cylinder block-to-bedplate mating surface as
shown (Fig. 120).
Fig. 117 Bedplate Pry Point Location
1 ± CYLINDER BLOCK
2 ± BEDPLATE
3 ± PRY POINT
Fig. 118 Crankshaft Thrust Washer Installation
1 ± CRANKSHAFT THRUST WASHER
9 - 68 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (3) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith 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
Universal 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. 22). Place
spring over stud on the table and lift compressing
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 measurements
are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
meet specifications.
MEASURING TIMING CHAIN STRETCH
NOTE: To access timing chain Refer to Timing
Chain Cover in Removal and Installation Section.
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N´m (30 ft. lbs.) torque with cylinder head installed
or 20 N´m (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaft
Fig. 20 Intake and Exhaust Valves
1 ± MARGIN
2 ± VALVE SPRING RETAINER LOCK GROOVE
3 ± STEM
4±FACE
Fig. 21 Refacing Valve Seats
1±STONE
2 ± PILOT
3 ± VALVE SEAT
4 ± SHROUD
Fig. 22 Testing Valve Spring for Compressed
Length
1 ± TORQUE WRENCH
2 ± VALVE SPRING TESTER
DN5.2L ENGINE 9 - 97
SERVICE PROCEDURES (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 Use a 2 step procedure so the valve guides are
reamed true in relation to the valve seat:
²Step 1ÐReam to 0.0763 mm (0.003 inch).
²Step 2ÐReam to 0.381 mm (0.015 inch).
REFACING VALVES AND VALVE SEATS
The intake and exhaust valves have a 43-1/4É to
43-3/4É face angle and a 44-1/4É to 44-3/4É seat angle
(Fig. 20).
VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 21). Valves with less than 1.190 mm
(0.047 inch) margin should be discarded.
VALVE SEATS
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 22).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained.(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 seatLIGHTLYwith 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
REAMER SIZES
REAMER O/S VALVE GUIDE SIZE
0.076 mm (0.003 in.) 8.026 - 8.052 mm
(0.316 - 0.317 in.)
0.381 mm (0.015 in.) 8.331 - 8.357 mm
(0.328 - 0.329 in.)
Fig. 20 Valve Face and Seat Angles
1 ± CONTACT POINT
VALVE FACE AND VALVE SEAT ANGLE CHART
ITEM DESCRIPTION SPECIFICATION
ASEAT WIDTH± 1.016 - 1.524 mm
INTAKE (0.040 - 0.060 in.)
SEAT WIDTH± 1.524 - 2.032 mm
EXHAUST (0.060 - 0.080 in.)
BFACE ANGLE
(INT. and EXT.) 43
1¤4É-433¤4É
CSEAT ANGLE
(INT. and EXT.) 44
1¤4É-443¤4É
DCONTACT
SURFACE Ð
Fig. 21 Intake and Exhaust Valves
1 ± MARGIN
2 ± VALVE SPRING RETAINER LOCK GROOVE
3 ± STEM
4±FACE
9 - 154 5.9L ENGINEDN
SERVICE PROCEDURES (Continued)