1999 DODGE DURANGO front end

Downloaded from www.Manualslib.com manuals search engine (4) Remove intake manifold. Refer to Intake Man-
ifold in this section for the correct procedure.
(5) Remove cylinder head covers.
(6) Remove timing case cover and timing chain.
(7) Remove rocker arms.
(8) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
(9) Remove distributor and lift out the oil pump
and distributor drive shaft.
(10) Remove camshaft thrust plate, note location of
oil tab (Fig. 54).
(11) Install a long bolt into front of camshaft to aid
in removal of the camshaft. Remove camshaft, being
careful not to damage cam bearings with the cam
lobes.
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2
inches) of its final position in cylinder block.
(2) Install Camshaft Gear Installer Tool C-3509
with tongue back of distributor drive gear (Fig. 55).
(3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block.Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in
thrust plate.Tighten bolts to 24 N´m (210 in. lbs.)
torque. Top edge of tab should be flat against thrust
plate in order to catch oil for chain lubrication.
(5) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(6) Place timing chain around both sprockets.
(7) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(8) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(9) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 56).
(10) Install the camshaft bolt/cup washer. Tighten
bolt to 68 N´m (50 ft. lbs.) torque.
(11) Measure camshaft end play. Refer to Specifica-
tions for proper clearance. If not within limits install
a new thrust plate.
(12) Each tappet reused must be installed in the
same position from which it was removed.When
camshaft is replaced, all of the tappets must be
replaced.
Fig. 53 Camshaft and Sprocket Assembly
1 ± THRUST PLATE
2 ± OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL
WITH CAMSHAFT
3 ± CAMSHAFT SPROCKET
Fig. 54 Timing Chain Oil Tab Installation
1 ± THRUST PLATE FRONT SIDE
2 ± CHAIN OIL TAB
3 ± THRUST PLATE REAR SIDE
Fig. 55 Camshaft Holding Tool C-3509 (Installed
Position)
1 ± SPECIAL TOOL C-3509
2 ± DRIVE GEAR
3 ± DISTRIBUTOR LOCK BOLT
9 - 112 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight-
ened. All bearing capbolts removed during service pro-
cedures are to be cleaned and oiled before installation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 58).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Tool C-3059.
(3)
Install the bearing caps. Clean and oil the bolts.
Tighten the capbolts to 115 N´m (85 ft. lbs.) torque.
(4) Install the oil pump.
(5) Install the oil pan.
(6) Start engine check for leaks.
DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
(1) Remove distributor, refer to Group 8D, Ignition
Systems for the proper procedure.
(2) Remove the intake manifold. Refer to Intake
Manifold in this section for correct procedure.
(3) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and thread down until a
tight fit is obtained (Fig. 59).
(4) Hold puller screw and tighten puller nut until
bushing is removed.
INSTALLATION
(1) Slide new bushing over burnishing end of Dis-
tributor Drive Shaft Bushing Driver/Burnisher Tool
C-3053. Insert the tool and bushing into the bore.
(2) Drive bushing and tool into position, using a
hammer (Fig. 60).
(3) As the burnisher is pulled through the bushing,
the bushing is expanded tight in the block and bur-
nished to correct size (Fig. 61).DO NOT ream this
bushing.CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
occur.
(4) Install the intake manifold.
DISTRIBUTOR INSTALLATION
NOTE: Before installing the distributor, the oil
pump drive shaft must be aligned to number one
cylinder.
(1) Rotate crankshaft until No.1 cylinder is at top
dead center on the firing stroke.
(2) When in this position, the timing mark of
vibration damper should be under ª0º on the timing
indicator.
(3) Install the shaft so that after the gear spirals
into place, it will index with the oil pump shaft. The
slot on top of oil pump shaft should be aligned
towards the left front intake manifold attaching bolt
hole (Fig. 62).
(4) Install distributor, refer to Group 8D, Ignition
Systems for the proper procedure.
Fig. 59 Distributor Driveshaft Bushing Removal
1 ± SPECIAL TOOL C-3052
2 ± BUSHING
Fig. 60 Distributor Driveshaft Bushing Installation
1 ± SPECIAL TOOL C-3053
2 ± BUSHING
Fig. 61 Burnishing Distributor Driveshaft Bushing
1 ± SPECIAL TOOL C-3053
2 ± BUSHING
9 - 114 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine PISTON AND CONNECTING ROD ASSEMBLY
REMOVAL
(1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.
(4) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block. Be sure to keep tops of pistons covered
during this operation.
(5) Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and
connecting rod assemblies, rotate crankshaft to cen-
ter the connecting rod in the cylinder bore and at
BDC.Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mat-
ing rod.
INSTALLATION
(1) Be sure that compression ring gaps are stag-
gered so that neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 65).
(3) Immerse the piston head and rings in clean
engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385).Be sure position of rings
does not change during this operation.(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con-
necting rod cap and cylinder bore number are the
same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 N´m (45 ft. lbs.) torque.
(9) Install the oil pan.
(10) Install the cylinder head.
(11) Install the engine into the vehicle.CRANKSHAFT
REMOVAL
NOTE: This procedure can be done in vehicle.
However the transmission must be removed first.
(1) If crankshaft is to be removed while engine is
in vehicle remove the transmission. Refer to Group
21, for correct procedure.
(2) Remove the oil pan.
(3) Remove the oil pump from the rear main bear-
ing cap.
(4) Remove the vibration damper.
(5) Remove the timing chain cover.
(6) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.
CAUTION: Support crankshaft before removing
main bearing caps. failure to do so will allow the
crankshaft to fall damaging the crankshaft.
(7) Using a suitable jack, support the crankshaft.
(8) Identify main bearing caps before removal.
Remove main bearing caps and bearings one at a
time.
(9) Lower the crankshaft out of the block.
(10) Remove and discard the crankshaft rear oil
seals.
(11) Remove and discard the front crankshaft oil
seal.
Fig. 65 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
9 - 116 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine interference. If tool does not fit, the cover must be
removed and installed properly.
(4) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal bore of cover.
(5) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 68). Seat
the oil seal in the groove of the tool.
(6) Position the seal and tool onto the crankshaft
(Fig. 69).
(7) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 70).
(8) Remove the vibration damper bolt and seal
installation tool.
(9) Inspect the seal flange on the vibration
damper.
(10) Install the vibration damper.
(11) Connect the negative cable to the battery.
CRANKSHAFT OIL SEALSÐREAR
The service seal is a 2 piece, viton seal. The upper
seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
The lower seal half can only be installed with the
rear main bearing cap removed.
UPPER SEAL ÐCRANKSHAFT REMOVED
REMOVAL
(1) Remove the crankshaft. Discard the old upper
seal.
INSTALLATION
(1) Clean the cylinder block rear cap mating sur-
face. Make sure the seal groove is free of debris.
Fig. 68 Placing Oil Seal on Installation Tool 6635
1 ± CRANKSHAFT FRONT OIL SEAL
2 ± INSTALL THIS END INTO SPECIAL TOOL 6635
Fig. 69 Position Tool and Seal onto Crankshaft
1 ± SPECIAL TOOL 6635
2 ± OIL SEAL
3 ± TIMING CHAIN COVER
Fig. 70 Installing Oil Seal
1 ± SPECIAL TOOL 6635
2 ± TIMING CHAIN COVER
9 - 118 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine DESCRIPTION SPECIFICATION
PISTON PIN
Clearance in Piston 0.00635 ± 0.01905 mm
(0.00025 ± 0.00075 in.)
Diameter 24.996 ± 25.001 mm
(0.9841 ± 0.9843 in.)
End Play NONE
Length 75.946 ± 76.454 mm
(2.990 ± 3.010 in.)
PISTON RINGS
Ring Gap
Compression Rings 0.254 ± 0.508 mm
(0.010 ± 0.020 in.)
Oil Control (Steel Rails) 0.254 ± 1.270 mm
(0.010 ± 0.050 in.)
Ring Side Clearance
Compression Rings 0.038 ± 0.076 mm
(0.0015 ± 0.0030 in.)
Oil Ring (Steel Rails) 0.06 ± 0.21 mm
(0.002 ± 0.008 in.)
Ring Width
Compression rings 1.971 ± 1.989 mm
(0.0776 ± 0.0783 in.)
Oil Ring (Steel Rails) ±
Max.3.848 ± 3.975 mm
(0.1515 ± 0.1565 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) 21É
Opens (BBDC) 60É
Duration 264É
Intake Valve
Closes (ATDC) 61É
Opens (BBDC) 10É
Duration 250É
Valve Overlap 31ÉOVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
U/S-O/S Item Identification Identification
Location
U/S Rod/ R or M R-1-4
ect.Milled flat on
No.8
.0254
mmMain (indicating
No. 1crankshaft
(0.001
in.)Journal and 4
connectingcounterweight.
rod journal)
and/or
M-2-3 ect.
(indicating
No. 2
and 3 main
bearing
journal)
O/S HydrauliclDiamond-
shaped
.2032
mmTappets stamp top pad
-
(.008 in.) front of engine
and flat
ground
on outside
surface of
each
O/S tappet
bore.
O/S Valve X Milled pad
.127 mm Stems adjacent to
two
(.005 in.) tapped holes
(3/8 in.) on
each
end of
cylinder
head.
DN5.2L ENGINE 9 - 131
SPECIFICATIONS (Continued)

Downloaded from www.Manualslib.com manuals search engine DESCRIPTION AND OPERATION
ENGINE
DESCRIPTION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
The engine lubrication system consists of a rotor
type oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1).
The engine serial number is stamped into a
machined pad located on the left, front corner of the
cylinder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 2).
ENGINE LUBRICATION SYSTEM
DESCRIPTION
A gear-type positive displacement pump (Fig. 3) is
mounted at the underside of the rear main bearing
cap. The pump uses a pick-up tube and screen
assembly to gather engine oil from the oil pan.
OPERATION
The pump draws oil through the screen and inlet
tube from the sump at the rear of the oil pan. The oil
is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery that
channels the oil up to the main gallery, which
extends the entire length on the right side of the
block. The oil then goes down to the No. 1 main bear-
ing, back up to the left side of the block, and into the
oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod
rotates. This oil throwoff lubricates the camshaft
lobes, distributor drive gear, cylinder walls, and pis-
ton pins.
Fig. 1 Firing Order
Fig. 2 Engine Identification Number
Fig. 3 Positive Displacement Oil PumpÐTypical
1 ± INNER ROTOR AND SHAFT
2 ± BODY
3 ± DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 ± COTTER PIN
5 ± RETAINER CAP
6 ± SPRING
7 ± RELIEF VALVE
8 ± LARGE CHAMFERED EDGE
9 ± BOLT
10 ± COVER
11 ± OUTER ROTOR
9 - 136 5.9L ENGINEDN

Downloaded from www.Manualslib.com manuals search engine CYLINDER HEAD COVER GASKET
DESCRIPTION
The cylinder head cover gasket is a steel-backed
silicone gasket, designed for long life usage (Fig. 7).
OPERATION
The steel-backed silicone gasket is designed to seal
the cylinder head cover for long periods of time
through extensive heat and cold, without failure. The
gasket is designed to be reusable.
CYLINDER HEAD
DESCRIPTION
The cast iron cylinder heads (Fig. 8) are mounted
to the cylinder block using ten bolts. The spark plugs
are located in the peak of the wedge between the
valves.
OPERATION
The cylinder head closes the combustion chamber
allowing the pistons to compress the air fuel mixture
to the correct ratio for ignition. The valves located in
the cylinder head open and close to either allow clean
air into the combustion chamber or to allow the
exhaust gases out, depending on the stroke of the
engine.
VALVES AND VALVE SPRINGS
DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 48.768 mm (1.92 inches) in
diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch)
wafer interia welded to the tip for durability. These
valves are not splayed.
ENGINE OIL PAN
DESCRIPTION
The stamped steel engine oil pan is located at the
bottom of the engine, and contains a drain plug for
draining the engine oil.
OPERATION
The oil pan holds the engine oil and seals and pro-
tects the engine lower components from contami-
nates.
CRANKSHAFT OIL SEALS
DESCRIPTION
The crankshaft rear seal is a two piece viton seal.
The crankshaft front seal is a one piece viton seal
with a steel housing. The front seal is located in the
engine front cover. One part of the two piece rear
seal is located in a slot in the number five (5) crank-
shaft main bore, the second part of the two piece seal
is located in the number five (5) main bearing cap.
OPERATION
The crankshaft seals prevent oil from leaking from
around the crankshaft, either from the rear of the
engine or from the engine front cover.
PISTON AND CONNECTING ROD
DESCRIPTION
The pistons are made of aluminum and have three
ring grooves, the top two grooves are for the compres-
sion rings and the bottom groove is for the oil control
ring. The connecting rods are forged steel and are
coined prior to heat treat. The piston pins are press
fit.
Fig. 7 Cylinder Head Cover Gasket V-8 Gas Engines
1 ± CYLINDER HEAD COVER GASKET
Fig. 8 Cylinder Head AssemblyÐV-8 Gas Engines
1 ± EXHAUST VALVE
2 ± SPARK PLUGS
3 ± EXHAUST VALVES
4 ± SPARK PLUGS
5 ± EXHAUST VALVE
6 ± INTAKE VALVES
7 ± INTAKE VALVES
9 - 140 5.9L ENGINEDN
DESCRIPTION AND OPERATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS 1. Misaligned or
deteriorated gaskets1. Replace gasket
2. Loose fastener,
broken or porous metal
part2. Tighten, repair or replace the part
3. Front or rear
crankshaft oil seal
leaking3. Replace seal
4. Leaking oil gallery
plug or cup plug4. Remove and reseal threaded plug. Replace cup style plug
5. Leaking intake 5. Replace gaskets
manifold cross-over
gaskets
EXCESSIVE OIL
CONSUMPTION
OR SPARK
PLUGS OIL
FOULED1. PCV System
malfunction1. Refer to group 25, Emission Control System for correct
operation
2. Intake manifold 2. Replace plenum
plenum pan gasket pan gasket
failure
3. Defective valve 3. Replace seals
stem seal(s)
4. Worn or broken
piston rings4. Hone cylinder bores. Install new rings
5. Scuffed pistons/
cylinder walls5. Hone cylinder bores and replace pistons as required
6. Carbon in oil control
ring groove6. Remove rings and de-carbon piston
7. Worn valve guides 6. Repair as
necessary
8. Piston rings fitted 8. Remove rings and
too tightly in grooves check ring end gap
and side clearance.
Replace if necessary
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPMs, the area of the suspected
leak has been found.
(4) Repair as required.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
DN5.9L ENGINE 9 - 145
DIAGNOSIS AND TESTING (Continued)