1999 DODGE DURANGO gas

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)

Downloaded from www.Manualslib.com manuals search engine (21) Remove the cylinder head retaining bolts.
(22) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, due to the design of the cylin-
der head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
INSTALLATION
NOTE: The cylinder head bolts are tightened using
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.
Necking can be checked by holding a straight edge
against the threads. If all the threads do not contact
the scale, the bolt should be replaced (Fig. 61).
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
(1) Clean the cylinder head and cylinder block
mating surfaces (Fig. 62).
(2) Position the new cylinder head gasket on the
locating dowels.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
(3) Position the cylinder head onto the cylinder
block. Make sure the cylinder head seats fully over
the locating dowels.NOTE: The four smaller cylinder head mounting
bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.
(4) Lubricate the cylinder head bolt threads with
clean engine oil and install the ten M11 bolts.
(5) Coat the four M8 cylinder head bolts with
MopartLock and Seal Adhesivethen install the
bolts.
NOTE: The cylinder head bolts are tightened using
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Tighten the bolts in sequence (Fig. 63) using
the following steps and torque values:
²Step 1: Tighten bolts 1±10, 20 N´m (15 ft. lbs.).
²Step 2: Tighten bolts 1±10, 47 N´m (35 ft. lbs.).
Tighten bolts 11±14, 25 N´m (18 ft. lbs.).
²Step 3: Tighten bolts 1±10, 90 degrees. Tighten
bolts 11±14, 30 N´m (22 ft. lbs.).
(7) Position the secondary chain onto the camshaft
drive gear, making sure one marked chain link is on
either side of the V8 mark on the gear and position
the gear onto the camshaft.
(8) Install the camshaft drive gear retaining bolt.
(9) Install the left side secondary chain guide.
(10) Install the cylinder head access plug.
(11) Re-set and Install the left side secondary
chain tensioner.
(12) Remove Special Tool 8515.
(13) Install the timing chain cover.
Fig. 61 Checking Cylinder Head Bolts for Stretching
(Necking)
1 ± STRETCHED BOLT
2 ± THREADS ARE NOT STRAIGHT ON LINE
3 ± THREADS ARE STRAIGHT ON LINE
4 ± UNSTRETCHED BOLT
Fig. 62 Proper Tool Usage for Surface Preparation
1 ± PLASTIC/WOOD SCRAPER
DN4.7L ENGINE 9 - 43
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine NOTE: The cylinder head is attached to the cylinder
block with fourteen bolts.
(21) Remove the cylinder head retaining bolts.
(22) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, do to the design of the cylinder
head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
INSTALLATION
NOTE: The cylinder head bolts are tightened using
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.
Necking can be checked by holding a straight edge
against the threads. If all the threads do not contact
the scale, the bolt should be replaced (Fig. 61).
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
(1) Clean the cylinder head and cylinder block
mating surfaces (Fig. 65).(2) Position the new cylinder head gasket on the
locating dowels.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
(3) Position the cylinder head onto the cylinder
block. Make sure the cylinder head seats fully over
the locating dowels.
NOTE: The four smaller cylinder head mounting
bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.
(4) Lubricate the cylinder head bolt threads with
clean engine oil and install the ten M10 bolts.
(5) Coat the four M8 cylinder head bolts with
Mopar Lock and Seal Adhesivethen install the
bolts.
NOTE: The cylinder head bolts are tightened using
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Tighten the bolts in sequence (Fig. 66) using
the following steps and torque values:
²Step 1: Tighten bolts 1±10, 20 N´m (15 ft. lbs.).
²Step 2: Tighten bolts 1±10, 47 N´m (35 ft. lbs.).
Tighten bolts 11±14, 25 N´m (18 ft. lbs.).
²Step 3: Tighten bolts 1±10, 90 degrees. Tighten
bolts 11±14, 30 N´m (22 ft. lbs.).
(7) Position the secondary chain onto the camshaft
drive gear, making sure one marked chain link is on
either side of the V8 mark on the gear and position
the gear onto the camshaft.
(8) Install the camshaft drive gear retaining bolt.
(9) Install the right side secondary chain guide.
(10) Install the cylinder head access plug.
(11) Re-set and install the right side secondary
chain tensioner.
(12) Remove Special Tool 8515.
(13) Install the timing chain cover.
Fig. 65 Proper Tool Usage For Surface Preparation
1 ± PLASTIC/WOOD SCRAPER
Fig. 66 Cylinder Head Tightening Sequence
DN4.7L ENGINE 9 - 45
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (3) Using Special Tool 8512, press damper onto
crankshaft (Fig. 72).
(4) Install then tighten crankshaft damper bolt to
175 N´m (130 ft. lbs.).
(5) Install fan blade assembly.(6) Install radiator upper shroud and tighten fas-
teners to 11 N´m (95 in. lbs.).
(7) Connect electrical connector for shroud fan.
(8) Install radiator upper hose.
(9) Install accessory drive belt.
(10) Refill cooling system.
(11) Connect negative cable to battery.
TIMING CHAIN COVER
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system and remove viscous fan
drive assembly. Refer to Group 7, Cooling System for
procedures.
(3) Remove radiator shroud. Refer to Group 7,
Cooling System for procedure.
(4) Disconnect both heater hoses at timing cover.
(5) Disconnect lower radiator hose at engine.
(6) Remove crankshaft damper. Refer to procedure
in this section.
(7) Remove accessory drive belt tensioner assembly
(Fig. 73).
(8) Remove the generator and A/C compressor.
(9) Remove cover and gasket (Fig. 74).
INSTALLATION
(1) Clean timing chain cover and block surface.
Inspect cover gasket and replace as necessary.
(2) Install cover and gasket. Tighten fasteners in
sequence as shown in (Fig. 74) to 54 N´m (40 ft. lbs.).
Fig. 70 Crankshaft DamperÐRemoval
1 ± SPECIAL TOOL 8513 INSERT
2 ± SPECIAL TOOL 1026
Fig. 71 Proper Assembly Method for Special Tool
8512
1 ± BEARING
2 ± NUT
3 ± THREADED ROD
4 ± BEARING HARDENED SURFACE (FACING NUT)
5 ± HARDENED WASHER
Fig. 72 Crankshaft DamperÐInstallation
1 ± SPECIAL TOOL 8512
9 - 48 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (12) Place blocks of wood between engine brackets
and lower mounts to provide stability to engine.
NOTE: Do not pry on oil pan or oil pan gasket.
Gasket is mounted to engine and does not come
out with oil pan.
(13) Remove the oil pan mounting bolts and oil
pan (Fig. 108).
(14) Unbolt oil pump pickup tube and remove tube
and oil pan gasket from 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. 108).
(4) Raise the engine and remove the blocks of
wood.
Fig. 104 Main Bearing Markings on Target Wheel
1 ± REARMOST CRANKSHAFT COUNTER WEIGHT
2 ± TARGET WHEEL
3 ± MAIN BEARING SELECT FIT MARKINGS
MAIN BEARING SELECTION CHARTÐ4.7L
GRADE SIZE mm
(in.)FOR USE WITH
MARKING JOURNAL SIZE
A0.008 mm
U/S63.488±63.496 mm
(0.0004 in.)
U/S(2.4996±2.4999 in.)
BNOMINAL 63.496±63.504 mm
(2.4999±2.5002 in.)
C0.008 mm
O/S63.504±63.512 mm
(0.0004 in.)
O/S(2.5002±2.5005 in.)
Fig. 105 Checking Crankshaft End PlayÐTypical
CRANKSHAFT END PLAY SPECIFICATION
CHART
New Part:0.052 - 0.282mm
Specification(0.002 - 0.011 in.)
Wear Limit:0.43mm
(0.017 in.)
Fig. 106 Structural Dust Cover Removal /
Installation
DN4.7L ENGINE 9 - 63
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)