1999 DODGE DURANGO drive axle

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 (5) Lower engine and install both the left and
right side engine mount through bolts (Fig. 107).
Tighten the nuts to 68 N´m (50 ft. lbs.).
(6) Remove jack and install oil filter.
(7) Install structural dust cover.
(8) Install exhaust pipe onto exhaust manifolds.
(9) Lower vehicle.
(10) Install intake manifold.
(11) Install throttle body resonator and air inlet
hose.
(12) Install upper fan shroud.
(13) Fill cooling system.
(14) Fill engine oil.(15) Start engine and check for leaks.
OIL PAN 4X4 VEHICLE
REMOVAL
NOTE: 4X4 vehicles equipped with a 4.7L engine
must have the front axle removed before the oil pan
can be removed.
(1) Remove the front axle from vehicle. Refer to
DIFFERENTIAL AND DRIVELINE.
(2) Remove the structural dust cover (Fig. 109).
Refer to procedure in this section.
(3) Drain the engine oil and remove oil filter.
NOTE: Do not pry on oil pan or oil pan gasket.
Gasket is mounted to engine and does not come
out with oil pan.
(4) Remove the oil pan mounting bolts and oil pan
(Fig. 110).
(5) Unbolt oil pump pickup tube and remove tube
and oil pan gasket from engine.
Fig. 107 Engine Mount Through Bolt and Nut
Removal / Installation
1 ± LOCKNUT AND WASHER
2 ± ENGINE MOUNT/INSULATOR
3 ± THROUGH BOLT
4 ± FRAME
Fig. 108 Oil Pan Mounting Bolts and Oil Pan
Fig. 109 Structural Dust Cover Removal /
Installation
Fig. 110 Oil Pan Mounting Bolts and Oil Pan
9 - 64 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
(1) Clean the oil pan gasket mating surface of the
bedplate and oil pan.
(2) Position the oil pan gasket and pickup tube
with new o-ring. Install the mounting bolt and nuts.
Tighten bolt and nuts to 28 N´m (20 ft. lbs.).
(3) Position the oil pan and install the mounting
bolts. Tighten the mounting bolts to 15 N´m (11 ft.
lbs.) in the sequence shown (Fig. 110).
(4) Install structural dust cover.
(5) Install oil filter.
(6) Install front axle. Refer to DIFFERENTIAL
AND DRIVELINE.
(7) Lower vehicle.
(8) Fill engine oil.
(9) Start engine check for leaks.
PISTON AND CONNECTING ROD
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the following components: (Refer to
procedures in this section)
²Oil pan and gasket/windage tray.
²Cylinder head covers.
²Timing chain cover.
²Cylinder head(s).
(3) If necessary, remove top ridge of cylinder bores
with a reliable ridge reamer before removing pistons
from cylinder block.Be sure to keep tops of pis-
tons covered during this operation.Pistons and
connecting rods must be removed from top of cylinder
block. When removing piston and connecting rod
assemblies from the engine, rotate crankshaft so the
each connecting rod is centered in cylinder bore.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods or caps, as damage to
connecting rods could occur
NOTE: Connecting rods and bearing caps are not
interchangeable and should be marked before
removing to ensure correct reassembly.
(4) Mark connecting rod and bearing cap positions
using a permanent ink marker or scribe tool (Fig.
111).
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as engine
damage may occur.
(5) Remove connecting rod cap. Install Special Tool
8507 Connecting Rod Guides into the connecting rod
being removed. Remove piston from cylinder bore.
Repeat this procedure for each piston being removed.CAUTION: Care must be taken not to nick crank-
shaft journals, as engine damage may occur
(6) Immediately after piston and connecting rod
removal, install bearing cap on the mating connect-
ing rod to prevent damage to the fractured cap and
rod surfaces.
(7) Carefully remove piston rings from piston(s),
starting from the top ring down.
PISTON RINGSÐINSTALLATION
(1) 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.
NOTE: Piston rings are installed in the following
order:
²Oil ring expander.
²Upper oil ring side rail.
²Lower oil ring side rail.
²No. 2 Intermediate piston ring.
²No. 1 Upper piston ring.
(2) Install the oil ring expander.
(3) Install upper side rail (Fig. 112) by placing one
end between the piston ring groove and the expander
ring. Hold end firmly and press down the portion to
be installed until side rail is in position. Repeat this
step for the lower side rail.
(4) Install No. 2 intermediate piston ring using a
piston ring installer (Fig. 113).
(5) Install No. 1 upper piston ring using a piston
ring installer (Fig. 113).
(6) Position piston ring end gaps as shown in (Fig.
114). It is important that expander ring gap is at
least 45É from the side rail gaps, but not on the pis-
ton pin center or on the thrust direction.
INSTALLATION
(1) Before installing piston and connecting rod
assemblies in to the bore, ensure all rings are in
position shown in (Fig. 114).
Fig. 111 Identify Connecting Rod to Cylinder
PositionÐTypical
DN4.7L ENGINE 9 - 65
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist.
(3) Install engine lifting (support) fixture.
(4) Remove front axle assembly. (Refer to Group 3,
Differential and Driveline in this publication.)
(5)Left mount insulator only.Remove starter
wires and starter motor assembly.
(6) Remove insulator to frame through bolt (Fig.
33).
(7) Raise engine slightly.
(8) Remove upper insulator to support bracket
stud nut and insulator to support through bolt.
(9) Remove engine mount insulator (Fig. 31) (Fig.
32).
(10) If engine support bracket is to be removed/re-
placed, remove support bracket to transmission bell
housing bolt(s) and three (3) support bracket to
engine block bolts. Remove support bracket (Fig. 31)
(Fig. 32).
INSTALLATIONÐ4WD
(1) If engine support brackets were removed,
install them and their fasteners (Fig. 31) (Fig. 32).
Tighten support bracket to block bolts to 41 N´m (30
ft. lbs.). Tighten support bracket to transmission bell-
housing bolt(s) to 88 N´m (65 ft. lbs.).
(2) Install Engine mount insulator and tighten
insulator to support bracket nut to 41 N´m (30 ft.
lbs.). Tighten insulator to support bracket through
bolt nut to 102 N´m (75 ft. lbs.).
(3) Lower engine and install insulator to frame
through bolt and nut (Fig. 33). Tighten nut to 95 N´m
(70 ft. lbs.).
(4) Install starter motor and mounting bolts.
Tighten bolts to 68 N´m (50 ft. lbs.).
(5) Connect starter wires.
(6) Remove engine lifting (support) fixture.
(7) Install front axle assembly. (Refer to Group 3,
Differential and Driveline).
(8) Lower the vehicle.
(9) Connect the negative cable to the battery.
Fig. 31 Right Engine Mount Insulator and Support
Bracket
1 ± ENGINE SUPPORT BRACKET
2 ± INSULATOR
3 ± FRONT AXLE
Fig. 32 Left Engine Mount Insulator and Support
Bracket
1 ± ENGINE SUPPORT BRACKET
2 ± INSULATOR
3 ± FRONT AXLE
DN5.2L ENGINE 9 - 101
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (9) Disconnect the accelerator linkage.
(10) Remove throttle body.
(11) Perform the Fuel System Pressure release
procedure (refer to Group 14, fuel System).
(12) Disconnect the fuel supply line.
(13) Disconnect the starter wires.
(14) Disconnect the oil pressure sending unit wire.
(15) Discharge the air conditioning system, if
equipped (refer to Group 24, Heating and Air Condi-
tioning for service procedures).
(16) Disconnect the air conditioning hoses.
(17) Disconnect the power steering hoses, if
equipped.
(18) Remove starter motor (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(19) Remove the generator (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(20) Raise and support the vehicle on a hoist.
(21) Disconnect exhaust pipe at manifold.
(22) Refer to Group 21, Transmissions for trans-
mission removal.
CAUTION: DO NOT lift the engine by the intake
manifold.
(23) Install an engine lifting fixture.
(24) The engine and front driving axle (engine/ax-
le/transmission) are connected through insulators
and support brackets. Separate the engine as follows:
²LEFT SIDEÐRemove 2 bolts attaching
(engine/pinion nose/transmission) bracket to trans-
mission bell housing. Remove 2 bracket to pinion
nose adaptor bolts. Separate engine from insulator by
removing upper nut washer assembly and bolt from
engine support bracket.
²RIGHT SIDEÐRemove 2 bracket to axle (dis-
connect housing) bolts and a bracket to bell housing
bolt. Separate engine from insulator by removing
upper nut washer assembly and bolt from engine
support bracket.
(25) Lower the vehicle.
(26) Install engine assembly on engine repair
stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Install the engine front mounts.
(5) Refer to Group, 21 Transmissions for transmis-
sion installation
(6) Install the inspection plate.
(7) Remove transmission support.
(8) Install exhaust pipe to manifold.
(9) Lower the vehicle.
(10) Remove engine lifting fixture.(11) Install the generator (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(12) Install starter motor (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(13) Connect power steering hoses, if equipped.
(14) Connect air conditioning hoses.
(15) Evacuate and charge the air conditioning sys-
tem, if equipped (refer to Group 24, Heater and Air
Conditioning for service procedures).
(16) Using a new gasket, install throttle body.
Tighten the throttle body bolts to 23 N´m (200 in.
lbs.) torque.
(17) Connect the accelerator linkage.
(18) Connect the starter wires.
(19) Connect the oil pressure sending unit wire.
(20) Install the distributor cap and wiring.
(21) Connect the vacuum supply lines to the
intake manifold.
(22) Connect the fuel supply lines.
(23) Install the radiator (refer to Group 7, Cooling
System). Connect the radiator hoses and heater
hoses.
(24) Install fan shroud in position.
(25) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure).
(26) Install the air cleaner.
(27) Install the battery.
(28) Warm engine and adjust.
(29) Install hood and line up with the scribe
marks.
(30) Road test vehicle.
INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain the cooling system. Refer to COOLING
SYSTEM.
(3) Remove the A/C compressor. Refer to HEAT-
ING and AIR CONDITIONING.
(4) Remove the generator. Refer to CHARGING
SYSTEM.
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner assembly and air inlet
hose.
(7) Perform the fuel pressure release procedure.
Refer to FUEL SYSTEM.
(8) Disconnect the fuel supply line from the fuel
rail. Refer to FUEL SYSTEM.
(9) Disconnect the accelerator linkage and, if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the coolant temperature sending
unit wire.
DN5.2L ENGINE 9 - 103
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 (2)Install the dowels in the cylinder block (Fig. 64).
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 N´m (215 in. lbs.)
torque.(8) Install the drain plug. Tighten drain plug to 34
N´m (25 ft. lbs.) torque.
(9) Lower transmission onto crossmember.
(10) Install rear support cushion mounting bolts.
Tighten bolts to 28 N´m (250 in. lbs.).
(11) Raise engine by way of oil pan with a wood
block placed between jack and oil pan.
(12) Remove through bolts from frame brackets
and lower engine. Install mount insulator through
bolts and tighten to 95 N´m (70 ft. lbs.).
(13) Install starter.
(14) Install transmission torque converter inspec-
tion cover.
(15) Install engine to transmission braces.
(16) Install exhaust pipe.
(17) Lower vehicle.
(18) Position throttle valve cable into bracket, then
attach to throttle body (Fig. 62A).
(19) Connect the distributor cap.
(20) Install dipstick.
(21) Install fan shroud.
(22) Install air cleaner assembly.
(23) Connect the negative cable to the battery.
(24) Fill crankcase with oil to proper level.
4WD
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
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).
(2) Install the dowels in the cylinder block (Fig.
64).
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 N´m (215 in. lbs.)
torque.
(8) Install the drain plug. Tighten drain plug to 34
N´m (25 ft. lbs.) torque.
(9) Install transmission inspection cover.
(10) Install engine mount support brackets and
insulators.
(11) Install front drive axle. Refer to DIFFEREN-
TIAL and DRIVELINE.
(12) Lower vehicle.
(13) Connect the distributor cap.
(14) Install dipstick.
(15) Connect the negative cable to the battery.
(16) Fill crankcase with oil to proper level.
Fig. 63 Fabrication of Alignment Dowels
1 ± 1 1/2º x 5/16º BOLT
2 ± DOWEL
3 ± SLOT
Fig. 64 Position of Dowels in Cylinder Block
1 ± DOWEL
2 ± DOWEL
3 ± DOWEL
4 ± DOWEL
9 - 115A 5.2L ENGINEDN
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 REMOVALÐ4WD
On 4WD vehicles the engine front support brackets
attach directly to engine block and the axle housing.
The brackets provide a solid interconnection for these
units (Fig. 35) (Fig. 36). Engine must be supported
during any service procedures involving the front
support assemblies.
(1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist.
(3) Install engine lifting (support) fixture.
(4) Remove front axle. (Refer to Group 3, Differen-
tial and Driveline in this publication.)
(5)Left mount insulator only.Remove starter
wires and starter motor assembly.
(6) Remove insulator to frame through bolt (Fig.
37).
(7) Raise engine slightly.
(8) Remove upper insulator to support bracket
stud nut and insulator to support through bolt.
(9) Remove engine mount insulator (Fig. 35) (Fig.
36).
(10) If engine support bracket is to be removed/re-
placed, remove support bracket to transmission bell
housing bolt(s) and three (3) support bracket to
engine block bolts. Remove support bracket (Fig. 35)
(Fig. 36).
Fig. 32 Engine Right Front Insulator MountÐ2WD
Vehicles
1 ± HEAT SHIELD
2 ± INSULATOR
Fig. 33 Engine Left Front Insulator MountÐ2WD
Vehicles
1 ± HEAT SHIELD
2 ± INSULATOR
Fig. 34 Engine Mount Insulator at Frame
1 ± NUT
2 ± INSULATOR
3 ± FRAME
4 ± THROUGH BOLT
DN5.9L ENGINE 9 - 159
REMOVAL AND INSTALLATION (Continued)