1999 DODGE DURANGO Group 8D

Downloaded from www.Manualslib.com manuals search engine (9) Tighten chain case cover bolts to 41 N´m (30 ft.
lbs.) torque. Tighten oil pan bolts to 24 N´m (215 in.
lbs.) torque.
(10) Remove the vibration damper bolt and seal
installation tool.
(11) Install vibration damper.
(12) Install water pump and housing assembly
using new gaskets (refer to Group 7, Cooling Sys-
tem). Tighten bolts to 41 N´m (30 ft. lbs.) torque.
(13) Install power steering pump (refer to Group
19, Steering).
(14) Install the serpentine belt (refer to Group 7,
Cooling System).
(15) Install the cooling system fan. Tighten the
bolts to 23 N´m (17 ft. lbs.) torque.
(16) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(17) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure).
(18) Connect the negative cable to the battery.
TIMING CHAIN
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove Timing Chain Cover. Refer to Timing
Chain Cover in this section for correct procedure.
(3) Re-install the vibration damper bolt finger
tight. Using a suitable socket and breaker bar, rotatethe crankshaft to align timing marks as shown in
(Fig. 52).
(4) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
INSTALLATION
(1) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(2) Place timing chain around both sprockets.
(3) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(4) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(5) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 52).
(6) Install the camshaft bolt. Tighten the bolt to 68
N´m (50 ft. lbs.) torque.
(7) 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.
(8) Install the timing chain cover.
CAMSHAFT
NOTE: The camshaft has an integral oil pump and
distributor drive gear (Fig. 53).
REMOVAL
(1) Remove the radiator. Refer to Group 7, Cooling
for the correct procedures.
(2) Remove the A/C Condenser (if equipped)
(3) Remove the engine cover.
Fig. 51 Installing Oil Seal
1 ± SPECIAL TOOL 6635
2 ± TIMING CHAIN COVER
Fig. 52 Alignment of Timing Marks
1 ± TIMING MARKS
DN5.2L ENGINE 9 - 111
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (13) Install distributor and distributor drive shaft.
(14) Install push rods and tappets.
(15) Install rocker arms.
(16) Install timing case cover.
(17) Install cylinder head covers.
(18) Install intake manifold.
(19) Install the engine cover.
(20) Install the A/C Condenser (if equipped).
(21) Install the radiator. Refer to Group 7, Cooling
for the correct procedures.
(22) Refill cooling system. Refer to Group 7, Cool-
ing for the correct procedures.
(23) Start engine check for leaks.
CAMSHAFT BEARINGS
REMOVAL
NOTE: This procedure requires that the engine is
removed from the vehicle.
(1) With engine completely disassembled, drive out
rear cam bearing core plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell. Drive
out bearing shells (Fig. 57).
INSTALLATION
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter.
(2) Position rear bearing in the tool. Install horse-
shoe lock and by reversing removal procedure, care-
fully drive bearing shell into place.
(3) Install remaining bearings in the same man-
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft.Be sure this plug does not leak.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 58).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig. 56 Alignment of Timing Marks
1 ± TIMING MARKSFig. 57 Camshaft Bearings Removal/Installation with
Tool C-3132-A
1 ± SPECIAL TOOL C-3132±A
2 ± MAIN BEARING OIL HOLE
Fig. 58 Upper Main Bearing Removal and
Installation with Tool C-3059
1 ± SPECIAL TOOL C-3059
2 ± BEARING
3 ± SPECIAL TOOL C-3059
4 ± BEARING
DN5.2L ENGINE 9 - 113
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 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 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 If oil pressure was low and pump is within specifi-
cations, inspect for worn engine bearings or other
reasons for oil pressure loss.
CYLINDER BLOCK
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
²The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.²The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
²The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.
Refer to Standard Service Procedures in the begin-
ning of this Group for the proper honing of cylinder
bores.
INTAKE MANIFOLD
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
EXHAUST MANIFOLD
CLEANING
Clean mating surfaces on cylinder head and mani-
fold, wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks, Inspect mating sur-
faces of manifold for flatness with a straight edge.
Seal surfaces must be flat within 0.1 mm (0.004 inch)
overall.
Fig. 90 Proper Installation of Retainer Cap
1 ± RETAINER CAP
2 ± CHAMFER
3 ± COTTER KEY
DN5.2L ENGINE 9 - 127
CLEANING AND INSPECTION (Continued)

Downloaded from www.Manualslib.com manuals search engine SERVICE DIAGNOSISÐGASOLINE ENGINES
PERFORMANCE DIAGNOSIS CHARTÐGASOLINE ENGINES
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL
NOT CRANK1. Weak or dead battery 1. Charge/Replace Battery. Refer to Group 8A,
Battery, for correct procedures. Check charging
system. Refer to Group 8C, Charging Systems, for
correct procedures.
2. Corroded or loose battery
connections2. Clean/tighten suspect battery/starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. Refer to Group 8B,
Starting Systems, for correct diagnostics/procedures
4. Seized accessory drive
component4. Remove accessory drive belt and attempt to start
engine. If engine starts, repair/replace seized
component.
5. Engine internal mechanical
failure or hydro-static lock5. Refer to Group 9, Engine, for correct diagnostics/
procedures
ENGINE CRANKS
BUT WILL NOT
START1. No spark 1. Check for spark. Refer to Group 8D, Ignition
System, for correct procedures.
2. No fuel 2. Perform fuel pressure test, and if necessary,
inspect fuel injector(s) and driver circuits. Refer to
Group 14, Fuel System, for correct procedures.
3. Low or no engine compression 3. Perform cylinder compression pressure test. Refer
to Group 9, Engine, for correct procedures.
ENGINE LOSS OF
POWER1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor (Refer to Group 8D,
Ignition System
3. Worn or incorrect gapped spark
plugs3. Clean plugs and set gap. (Refer to Group 8D,
Ignition System)
4. Dirt or water in fuel system 4. Clean system and replace fuel filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression
9. Burned, warped, or pitted valves 9. Install/Reface valves as necessary
10. Plugged or restricted exhaust
system10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted cables
12. Faulty ignition coil 12. Test and replace, as necessary (Refer to Group
8D, Ignition System)
ENGINE STALLS
OR ROUGH IDLE1. Carbon build-up on throttle plate 1. Remove throttle body and de-carbon. (Refer to
Group 14 for correct procedures)
2. Engine idle speed too low 2. Check Idle Air Control circuit. (Refer to Group 14,
Fuel System)
9 - 142 5.9L ENGINEDN
DIAGNOSIS AND TESTING (Continued)

Downloaded from www.Manualslib.com manuals search engine CONDITION POSSIBLE CAUSES CORRECTION
3. Worn or incorrectly gapped spark
plugs3. Replace or clean and re-gap spark plugs (Refer to
group 8D, Ignition System)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or
crossed5. Check for correct firing order or replace spark plug
cables. (Refer to Group 8D, Ignition System for
correct procedures.)
6. Faulty coil 6. Test and replace, if necessary (Refer to group 8D,
Ignition System)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket and vacuum hoses.
Replace if necessary
8. EGR valve leaking or stuck open 8. Test and replace, if necessary (Refer to group 25,
Emission Control Systems)
ENGINE MISSES
ON
ACCELERATION1. Worn or incorrectly gapped spark
plugs1. Replace spark plugs or clean and set gap. (Refer
to group 8D, Ignition System)
2. Spark plug cables defective or
crossed2. Replace or rewire secondary ignition cables. Refer
to Group 8D, Ignition System
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary (refer to group 8D,
Ignition System)
MECHANICAL DIAGNOSIS CHARTÐGASOLINE ENGINES
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES/
LIFTERS1. High or low oil level
in crankcase1. Check for correct oil level. Adjust oil level by draining or adding
as needed
2. Thin or diluted oil 2. Change oil (Refer to Engine Oil Service in this group)
3. Low oil pressure 3. Check engine oil level. If ok, Perform oil pressure test. Refer to
this group for engine oil pressure test/specifications
4. Dirt in tappets/lash
adjusters4. Clean/replace hydraulic tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms and replace worn arms as
needed
7. Worn tappets/lash
adjusters7. Install new hydraulic tappets/lash adjusters
8. Worn valve guides 8. Inspect all valve guides and replace as necessary
9. Excessive runout of
valve seats or valve
faces9. Grind valves and seats
DN5.9L ENGINE 9 - 143
DIAGNOSIS AND TESTING (Continued)