1998 DODGE DURANGO torque

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 Fig. 16 Camshaft Sprocket InstallationÐRight
Cylinder Head
1 ± TORQUE WRENCH
2 ± SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 ± LEFT CAMSHAFT SPROCKET
4 ± RIGHT CAMSHAFT SPROCKET
Fig. 17 Measuring Secondary Timing Chains For
Stretch
1 ± SECONDARY TENSIONER ARM
2 ± SECONDARY CHAIN TENSIONER PISTON
Fig. 18 Moly Coated Piston
1 ± MOLY COATED
2 ± MOLY COATED
Fig. 19 Bore GaugeÐTypical
1 ± FRONT
2 ± BORE GAUGE
3 ± CYLINDER BORE
4 ± 49.5 MM
(1±15/16 in)
DN4.7L ENGINE 9 - 23
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 (20) Install both breathers. Connect tube to both
crankcase breathers (Fig. 44).
(21) Connect throttle and speed control cables.
(22) Install throttle body resonator assembly and
air inlet hose. Tighten clamps 4 N´m (35 in. lbs.).
(23) Raise vehicle.
(24) Install transmission to engine mounting bolts.
Tighten the bolts to 41 N´m (30 ft. lbs.).
(25) Install torque converter bolts (Automatic
Transmission Only).
(26) Connect crankshaft position sensor (Fig. 43).
(27)4X4 vehiclesPosition and install the axle
isolator bracket onto the axle, transmission and
engine block. Tighten bolts to specification. Refer to
Specifications in this section.
(28) Install starter.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.(29) Install structural cover. Refer to Structural
Cover in this section.
(30) Install exhaust crossover pipe.
(31) Install engine block heater power cable, If
equipped.
(32)4X4 vehiclesConnect axle vent tube to left
side engine mount.
(33) Lower vehicle.
(34) Check and fill engine oil.
(35) Recharge the A/C system.
(36) Refill the engine cooling system. Refer to
COOLING SYSTEM.
(37) Install the battery tray and battery.
(38) Connect the battery positive and negative
cables.
(39) Start the engine and check for leaks.
Fig. 46 Throttle Body Connection Points
1 ± THROTTLE BODY
2 ± TPS
3 ± IAC MOTOR
4 ± IAT SENSOR
5 ± MOUNTING SCREWS
Fig. 47 Engine Lifting Fixture Attachment Locations
1 ± ATTACHING LOCATION
2 ± ADJUSTABLE HOOK
3 ± SPECIAL TOOL 8347 ENGINE LIFT FIXTURE
4 ± ATTACHING LOCATIONS
9 - 34 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
(1) Install exhaust manifold and gasket from below
engine compartment.
(2) Install lower exhaust manifold fasteners. DO
NOT tighten until all fasteners are in place.
(3) Lower vehicle and install upper exhaust mani-
fold fasteners. Tighten all manifold bolts starting at
center and working outward to 25 N´m (18 ft. lbs.).CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(4) Install exhaust manifold heat shield. Tighten
fasteners to 8 N´m (72 in. lbs.), then loosen 45
degrees.
(5) Install starter and fasteners.
(6) Connect exhaust pipe to manifold.
(7) Connect heater hoses at engine.
(8) Install fastener attaching A/C accumulator.
Fig. 52 Exhaust ManifoldÐRight
ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE
1 Stud (Qty 2)
25 N´m
(18 ft. lbs.)4 Nut (Qty 2) 8 N´m
(72 in. lbs.), then
loosen 45
degrees 2 Bolt (Qty 4) 5 Nut (Qty 2)
3 Stud (Qty 2)
DN4.7L ENGINE 9 - 37
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (12) Remove cylinder head cover retaining bolts.
(13) Remove cylinder head cover.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.INSTALLATION
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
Fig. 53 Exhaust ManifoldÐLeft
ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE
1 Stud (Qty 2)
25 N´m (18 ft.
lbs.)4 Nut (Qty 2) 8 N´m (72 in.
lbs.), then loosen
45 degrees 2 Bolt (Qty 4) 5 Nut (Qty 2)
3 Stud (Qty 2)
DN4.7L ENGINE 9 - 39
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the
engine cylinder head cover. Prolonged contact with
other objects may wear a hole in the cylinder head
cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Install cylinder head cover and hand start all
fasteners. Verify that all double ended studs are in
the correct location shown in (Fig. 55).
(3) Tighten cylinder head cover bolts and double
ended studs to 12 N´m (105 in. lbs).
(4) Install right rear breather tube and filter
assembly.(5) Connect injector, ignition coil electrical connec-
tors and harness retaining clips.
(6) Install the oil fill tube.
(7) Install PCV hose.
(8) Install heater hoses.
(9) Install air conditioning compressor retaining
bolts.
(10) Install accessory drive belt
(11) Fill Cooling system
(12) Install air cleaner assembly, resonator assem-
bly and air inlet hose.
(13) Connect battery negative cable.
ROCKER ARMS
REMOVAL
NOTE: Disconnect the battery negative cable to
prevent accidental starter engagement.
(1) Remove the cylinder head cover. Refer to Cyl-
inder Head Cover in this section.
(2) For rocker arm removal on cylinders 3 and 5
Rotate the crankshaft until cylinder #1 is at TDC
exhaust stroke.
(3) For rocker arm removal on cylinders 2 and 8
Rotate the crankshaft until cylinder #1 is at TDC
compression stroke.
(4) For rocker arm removal on cylinders 4 and 6
Rotate the crankshaft until cylinder #3 is at TDC
compression stroke.
(5) For rocker arm removal on cylinders 1 and 7
Rotate the crankshaft until cylinder #2 is at TDC
compression stroke.
(6) Using special tool 8516 press downward on the
valve spring, remove rocker arm (Fig. 56).
INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil
prior to installation.
(1) For rocker arm installation on cylinders 3 and
5 Rotate the crankshaft until cylinder #1 is at TDC
exhaust stroke.
(2) For rocker arm installation on cylinders 2 and
8 Rotate the crankshaft until cylinder #1 is at TDC
compression stroke.
(3) For rocker arm installation on cylinders 4 and
6 Rotate the crankshaft until cylinder #3 is at TDC
compression stroke.
Fig. 54 Cylinder Head CoverÐLeft
ITEM DESCRIPTION TORQUE
1 Cover
Fasteners12 N´m (105 in. lbs.)
Fig. 55 Cylinder Head CoverÐRight
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 N´m (105 in. lbs.)
9 - 40 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)