1998 DODGE DURANGO Transfer case

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 (6) Coat the crankshaft main bearing journals
with clean engine oil and position the bedplate onto
the cylinder block.
NOTE: Lubricate the bedplate retaining bolts with
clean engine oil prior to installation.
(7) Install the bedplate retaining bolts, making
sure to place the stud bolts in the correct location,
Torque the bolts in the sequence shown (Fig. 121).
²Tighten boltsA± Lto 54 N´m (40 ft. lbs.)
²Tighten bolts1±10to 2.8 N´m (25 in. lbs.)
²Turn bolts1±10an additional 90É.²Tighten boltsA1± A6to 27 N´m (20 ft. lbs.)
(8) Measure crankshaft end play. Refer to Crank-
shaft Main Bearings in this section for procedure.
(9) Install the connecting rods and measure side
clearance. Refer to Connecting Rod Bearings in this
section for procedure.
(10) Position the oil pan gasket/windage tray,
using a new o-ring, install the oil pickup tube.
Torque the bolt to 28N´n (20 ft. lbs.) torque the nuts
to 28N´m (20 ft. lbs.).
(11) Install the oil pan. Torque the retaining bolts
to 15 N´m (11 ft. lbs.) in the sequence shown (Fig.
122).
(12) Install the engine.
FLEXPLATE
REMOVAL
(1) Remove the transmission. Refer to Group 21,
Transmission and Transfer Case for procedure.
(2) Remove the bolts and flexplate.
INSTALLATION
(1) Position the flexplate onto the crankshaft and
install the bolts hand tight.
(2) Tighten the flexplate retaining bolts to 60 N´m
(45 ft. lbs.) in the sequence shown (Fig. 123).
(3) Install the transmission.
OIL PUMP
REMOVAL
(1) Remove the oil pan and pick-up tube. Refer to
the procedure in this section.
(2) Remove the timing chain cover. Refer to the
procedure in this section.
(3) Remove the timing chains and tensioners.
Refer to Timing Chain and Sprockets in this section.
(4) Remove the four bolts, primary timing chain
tensioner and the oil pump.
INSTALLATION
(1) Position the oil pump onto the crankshaft and
install two oil pump retaining bolts.
(2) Position the primary timing chain tensioner
and install the two retaining bolts.
(3) Tighten the oil pump and primary timing chain
tensioner retaining bolts to 28 N´m (250 in. lbs.) in
the sequence shown (Fig. 124).
(4) Install the secondary timing chain tensioners
and timing chains.
(5) Install the timing chain cover.
(6) Install the pick-up tube and oil pan.
Fig. 119 Cutting Aplicator to Achieve 2.5mm (0.100
in.) Bead
1 ± CUT HERE
Fig. 120 Cylinder Block-to-Bedplate Sealent Bead
Location
1 ± CYLINDER BLOCK
2 ± SEALANT BEAD LOCATION
DN4.7L ENGINE 9 - 69
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CRANKSHAFT OIL SEALÐREAR
REMOVAL
NOTE: This procedure can be preformed in vehicle.(1) If being preformed in vehicle, remove the
transmission. Refer to Group 21, Transmission and
Transfer Case.
(2) Remove the flexplate. Refer to procedure in
this section.
NOTE: The crankshaft oil seal CAN NOT be reused
after removal.
NOTE: The crankshaft rear oil seal remover Special
Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Using Special Tool 8506 (Fig. 132), remove the
crankshaft rear oil seal.
INSTALLATION
(1) Position the magnetic seal guide Special Tool
8349±2 (Fig. 133) onto the crankshaft rear face. Then
position the crankshaft rear oil seal onto the guide.
(2) Using Special Tools 8349 Crankshaft Rear Oil
Seal Installer and C-4171 Driver Handle (Fig. 134),
with a hammer, tap the seal into place. Continue to
tap on the driver handle until the seal installer seats
against the cylinder block crankshaft bore.
(3) Install the flexplate.
(4) If removed, install the transmission.
Fig. 130 Proper Assembly Method for Special Tool
8512
1 ± BEARING
2 ± NUT
3 ± THREADED ROD
4 ± BEARING HARDENED SURFACE (FACING NUT)
5 ± HARDENED WASHER
Fig. 131 Crankshaft DamperÐInstallation
1 ± SPECIAL TOOL 8512
Fig. 132 Crankshaft Rear Oil Seal Removal
1 ± REAR CRANKSHAFT SEAL
2 ± SPECIAL TOOL 8506
DN4.7L ENGINE 9 - 73
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine TORQUE SPECIFICATIONS
TORQUE CHART 5.2L ENGINE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 50 Ð
Camshaft Thrust PlateÐBolts 24 Ð 210
Chain Case CoverÐBolts 41 30 Ð
Connecting Rod CapÐBolts 61 45 Ð
Main Bearing CapÐBolts 115 85 Ð
Crankshaft PulleyÐBolts 24 Ð 210
Cylinder HeadÐBolts
Step 1 68 50 Ð
Step 2 143 105 Ð
Cylinder Head CoverÐBolts 11 Ð 95
Engine Support Bracket to
BlockÐ41 30 Ð
Bolts (4WD)
Exhaust Manifold to Cylinder
HeadÐ34 25 Ð
Bolts/Nuts
FlywheelÐBolts 75 55 Ð
Front InsulatorÐThrough
bolt/nut95 70 Ð
Front Insulator to Support
BracketÐ
Stud Nut (4WD) 41 30 Ð
Through Bolt/Nut 102 75 Ð
Front Insulator to BlockÐ 95 70 Ð
Bolts (2WD)
GeneratorÐMounting Bolts 41 30 Ð
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 Ð 215
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐMounting Bolts 41 30 Ð
Oil Pump CoverÐBolts 11 Ð 95
Rear Insulator to BracketÐ
Through68 50 Ð
Bolt (2WD)
Rear Insulator to
Crossmember41 30 Ð
Support BracketÐNut (2WD)
Rear Insulator to
CrossmemberÐ68 50 Ð
Nuts (4WD)
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Rear Insulator to
TransmissionÐ68 50 Ð
Bolts (4WD)
Rear Insulator BracketÐBolts 68 50 Ð
(4WD Automatic)
Rear Support Plate to
Transfer Case41 30 Ð
ÐBolts
Rocker ArmÐBolts 28 21 Ð
Spark Plugs 41 30 Ð
Starter MotorÐMounting
Bolts68 50 Ð
Thermostat HousingÐBolts 25 Ð 225
Throttle BodyÐBolts 23 Ð 200
Torque Converter Drive
PlateÐBolts31 Ð 270
Transfer Case to Insulator
Mounting204 150 Ð
PlateÐNuts
Transmission Support
BracketÐ68 50 Ð
Bolts (2WD)
Vibration DamperÐBolt 183 135 Ð
Water Pump to Timing Chain
Case41 30 Ð
CoverÐBolts
SPECIAL TOOLS
5.2L ENGINE
Oil Pressure Gauge C-3292
9 - 132 5.2L ENGINEDN
SPECIFICATIONS (Continued)

Downloaded from www.Manualslib.com manuals search engine SPECIFICATIONS
TORQUE CHART 5.9L ENGINE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 50 Ð
Camshaft Thrust PlateÐBolts 24 Ð 210
Timing Chain Case CoverÐ
Bolts41 30 Ð
Connecting Rod CapÐBolts 61 45 Ð
Main Bearing CapÐBolts 115 85 Ð
Crankshaft PulleyÐBolts 24 Ð 210
Cylinder HeadÐBolts
Step 1 68 50 Ð
Step 2 143 105 Ð
Cylinder Head CoverÐBolts 11 Ð 95
Engine Support Bracket to
BlockÐ41 30 Ð
Bolts (4WD)
Exhaust Manifold to Cylinder
HeadÐ34 25 Ð
Bolts/Nuts
FlywheelÐBolts 75 55 Ð
Front InsulatorÐThrough
bolt/nut95 70 Ð
Front Insulator to Support
Bracket
ÐStud Nut (4WD) 41 30 Ð
ÐThrough Bolt/Nut (4WD) 102 75 Ð
Front Insulator to BlockÐ
Bolts (2WD)95 70 Ð
GeneratorÐMounting Bolt 41 30 Ð
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 Ð 215
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐAttaching Bolts 41 30 Ð
Oil Pump CoverÐBolts 11 Ð 95
Rear Insulator to BracketÐ 68 50 Ð
Through-Bolt (2WD)
Rear Insulator to
Crossmember41 30 Ð
Support BracketÐNut (2WD)
Rear Insulator to
CrossmemberÐ68 50 Ð
Nuts (4WD)
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Rear Insulator to
TransmissionÐ68 50 Ð
Bolts (4WD)
Rear Insulator BracketÐBolts 68 50 Ð
(4WD Automatic)
Rear Support Bracket to 41 30 Ð
Crossmember FlangeÐNuts
Rear Support Plate to
Transfer41 30 Ð
CaseÐBolts
Rocker ArmÐBolts 28 21 Ð
Spark Plugs 41 30 Ð
Starter MotorÐMounting Bolts 68 50 Ð
Thermostat HousingÐBolts 25 Ð 225
Throttle BodyÐBolts 23 Ð 200
Torque Converter Drive
PlateÐBolts31 Ð 270
Transfer Case to Insulator 204 105 Ð
Mounting PlateÐNuts
Transmission Support
BracketÐ68 50 Ð
Bolts (2WD)
Vibration DamperÐBolt 244 180 Ð
Water Pump to Timing Chain 41 30 Ð
Case CoverÐBolts
SPECIAL TOOLS
5.9L ENGINE
Oil Pressure Gauge C-3292
DN5.9L ENGINE 9 - 189
SPECIFICATIONS (Continued)