1999 DODGE DURANGO engine

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 sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 23).
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
(5) If chain is not satisfactory, remove camshaft
sprocket attaching bolt and remove timing chain with
crankshaft and camshaft sprockets.
(6) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(7) Place timing chain around both sprockets.
(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(10) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 24).
(11) Install the camshaft bolt. Tighten the bolt to
47 N´m (35 ft. lbs.) torque.
(12) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.
PISTONSÐFITTING
Piston and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylin-
der wall is 0.013-0.038 mm (0.0005-0.0015 inch) at
21ÉC (70ÉF).Piston diameter should be measured at the top of
skirt, 90É to piston pin axis. Cylinder bores should be
measured halfway down the cylinder bore and trans-
verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
Check the pistons for taper and elliptical shape
before they are fitted into the cylinder bore (Fig. 25).
PISTON RINGSÐFITTING
(1) Measurement of end gaps:
(a) Measure piston ring gap 2 inches from bot-
tom of cylinder bore. An inverted piston can be
used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measur-
ing.
(b) Insert feeler gauge in the gap. The top com-
pression ring gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compression
Fig. 23 Measuring Timing Chain Wear and Stretch
1 ± TORQUE WRENCH
2 ± 3.175 MM
(0.125 IN.)
Fig. 24 Alignment of Timing Marks
1 ± TIMING MARKS
Fig. 25 Piston Measurements
1 ± 49.53 mm
(1.95 IN.)
9 - 98 5.2L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine ring gap should be between 0.508-0.762 mm (0.020-
0.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be prop-
erly filed to the correct dimension. Rings with
excess gaps should not be used.
(2) Install rings and confirm ring side clearance:
(a) Install oil rings being careful not to nick or
scratch the piston. Install the oil control rings
according to instructions in the package. It is not
necessary to use a tool to install the upper and
lower rails. Insert oil rail spacer first, then side
rails.
(b) Install the second compression rings using
Installation Tool C-4184. The compression rings
must be installed with the identification mark faceup (toward top of piston) and chamfer facing down.
An identification mark on the ring is a drill point,
a stamped letter ªOº, an oval depression or the
word TOP (Fig. 26) (Fig. 28).
(c) Using a ring installer, install the top com-
pression ring with the chamfer facing up (Fig. 27)
(Fig. 28). An identification mark on the ring is a
drill point, a stamped letter ªOº, an oval depression
or the word TOP facing up.
(d) Measure side clearance between piston ring
and ring land. Clearance should be 0.074-0.097 mm
(0.0029-0.0038 inch) for the compression rings. The
steel rail oil ring should be free in groove, but
should not exceed 0.246 mm (0.0097 inch) side
clearance.
(e) Pistons with insufficient or excessive side
clearance should be replaced.
PISTON MEASUREMENT CHART
PISTON A DIA = PISTON BORE
SIZE DIAMETER DIAMETER
MIN. MAX. MIN. MAX.
mm
(in.)mm
(in.)mm
(in.)mm (in.)
AÐÐÐ Ð
B101.580 101.592 101.605 101.618
(3.9992) (3.9997) (4.0002) (4.0007)
C101.592 101.605 101.618 101.630
(3.9997) (4.0002) (4.0007) (4.0012)
D101.605 101.618 101.630 101.643
(4.0002) (4.0007) (4.0012) (4.0017)
EÐÐÐ Ð
DESCRIPTION SPECIFICATION
PISTON PIN BORE 25.007 - 25.015 mm
(.9845 -.9848 in.)
RING GROOVE
HEIGHT
OIL RAIL 4.033 - 4.058 mm
(.1588 -.1598 in.)
COMPRESSION
RAIL1.529 - 1.554 mm
(.0602 -.0612 in.)
TOTAL FINISHED 470.862 grams
WEIGHT (16.6076.0706 ounces)
Fig. 26 Second Compression Ring Identification
(Typical)
1 ± SECOND COMPRESSION RING (BLACK CAST IRON)
2 ± CHAMFER
3 ± TWO DOTS
Fig. 27 Top Compression Ring Identification
(Typical)
1 ± TOP COMPRESSION RING (GRAY IN COLOR)
2 ± CHAMFER
3 ± ONE DOT
DN5.2L ENGINE 9 - 99
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine CONNECTING ROD BEARINGSÐFITTING
Fit all rods on a bank until completed. DO NOT
alternate from one bank to another, because connect-
ing rods and pistons are not interchangeable from
one bank to another.
The bearing caps are not interchangeable and
should be marked at removal to ensure correct
assembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing shell,
make certain that the V-groove in the shell is in line
with the V-groove in the cap. This provides lubrica-
tion of the cylinder wall in the opposite bank.The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
caps.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 inch).
Bearings are available in 0.025 mm (0.001 inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under-
size.Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing half. DO
NOT file the rods or bearing caps.
CRANKSHAFT MAIN BEARINGSÐFITTING
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter-
changeable. Lower main bearing halves of No.2 and 4
are interchangeable.
Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT
interchangeable with any other bearing halves in the
engine (Fig. 30). Bearing shells are available in stan-
dard and the following undersizes: 0.25 mm (0.001
inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
Never install an undersize bearing that will reduce
clearance below specifications.
REMOVAL AND INSTALLATION
ENGINE MOUNTSÐFRONT
REMOVAL
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. 31) (Fig. 32). Engine must be supported
during any service procedures involving the front
support assemblies.
Fig. 28 Compression Ring Chamfer Location
(Typical)
1 ± CHAMFER
2 ± TOP COMPRESSION RING
3 ± SECOND COMPRESSION RING
4 ± PISTON
5 ± CHAMFER
Fig. 29 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
Fig. 30 Main Bearing Identification
9 - 100 5.2L ENGINEDN
SERVICE PROCEDURES (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 ENGINE MOUNTÐREAR
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Support the transmission with a transmission
jack.
(4) Remove stud nuts holding the insulator to the
crossmember (Fig. 34).
(5) Raise rear of transmission SLIGHTLY.
(6) Remove bolts holding the insulator to the insu-
lator bracket (Fig. 34). Remove the insulator.
INSTALLATION
(1) If the insulator bracket was removed, install
the bracket to the transmission (Fig. 34). Tighten the
bolts to 28 N´m (250 in. lbs.) torque.
(2) Install the bolts holding insulator to insulator
bracket. Tighten the bolts to 28 N´m (250 in. lbs.)
torque.
(3) Lower rear of transmission while aligning the
insulator studs into the mounting support bracket.Install stud nuts and tighten to 28 N´m (250 in. lbs.)
torque.
(4) Remove the transmission jack.
(5) Lower the vehicle.
(6) Connect the negative cable to the battery.
ENGINE ASSEMBLY
REMOVAL
(1) Scribe hood hinge outlines on hood. Remove the
hood.
(2) Disconnect the battery negative cable.
(3) Drain cooling system (refer to Group 7, Cooling
System for the proper procedure).
(4) Remove the air cleaner.
(5) Disconnect the radiator and heater hoses.
Remove radiator (refer to Group 7, Cooling System
for the correct procedures).
(6) Set fan shroud aside.
(7) Disconnect the vacuum supply lines from the
intake manifold.
(8) Remove the distributor cap and wires.
Fig. 33 Engine Mount Insulator at Frame
1 ± NUT
2 ± ENGINE SUPPORT BRACKET
3 ± INSULATOR
4 ± NUT
5 ± THROUGH BOLT
6 ± FRAME
7 ± FRONT AXLE
Fig. 34 Rear Mount Insulator
1 ± AUTOMATIC TRANSMISSION
2 ± INSULATOR BRACKET
3 ± INSULATOR
4 ± CROSSMEMBER
9 - 102 5.2L ENGINEDN
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 (13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 35). Dis-
card the throttle body gasket.
INSTALLATION
(1) If the plenum pan was removed, position pan
gasket and pan.
(2) Install plenum pan retaining bolts. (Fig. 36).
(3) Tighten plenum pan mounting bolts as follows:
²Step 1. Tighten bolts to 5.4 N´m (24 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check all bolts are at 9.5 N´m (84 in.
lbs.)
(4) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N´m
(200 in. lbs.) torque.
(5) Apply a bead of Mopar Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
The sealant bead height should be slightly higher
than the cross-over gaskets, approximately 5 mm (0.2
in). An excessive amount of sealant is not required to
ensure a leak proof seal, and an excessive amount of
sealant may reduce the effectiveness of the flange
gasket.
(6) Install the front and rear cross-over gaskets
onto the engine (Fig. 37).
(7) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face ofthe block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 38). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(8) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. long studs
at the front and rear of the manifold will help to
align the intake manifold. After intake manifold is in
Fig. 35 Throttle Body Assembly
1 ± FUEL RAIL ASSEMBLY
2 ± FUEL RAIL MOUNTING BOLTS
3 ± FUEL RAIL CONNECTING HOSES
Fig. 36 Plenum Pan Bolt Tightening Sequence
Fig. 37 Cross-Over Gaskets
1 ± FRONT CROSS-OVER GASKET
2 ± REAR CROSS-OVER GASKET
9 - 104 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)