1999 DODGE DURANGO Seat

Downloaded from www.Manualslib.com manuals search engine DISASSEMBLY AND ASSEMBLY
VALVE SERVICE
VALVE GUIDES
Measure valve stem guide clearance as follows:
(1) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 75). The special
sleeve places the valve at the correct height for
checking with a dial indicator.(2) Attach Dial Indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 76).
(3) Move valve to and from the indicator. The total
dial indicator reading should not exceed 0.432 mm
(0.017 inch). Ream the guides for valves with over-
size stems if dial indicator reading is excessive or if
the stems are scuffed or scored.
(4) Service valves with oversize stems are avail-
able as shown below.
(5) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve.Ream the
valve guides from standard to 0.381 mm (0.015
inch). Use a 2 step procedure so the valve
guides are reamed true in relation to the valve
seat:
²Step 1ÐReam to 0.0763 mm (0.003 inch).
²Step 2ÐReam to 0.381 mm (0.015 inch).
Fig. 74 Core Hole Plug Removal
1 ± CYLINDER BLOCK
2 ± REMOVE PLUG WITH PLIERS
3 ± STRIKE HERE WITH HAMMER
4 ± DRIFT PUNCH
5 ± CUP PLUG
Fig. 75 Positioning Valve with Tool C-3973
1 ± VALVE
2 ± SPACER TOOL
Fig. 76 Measuring Valve Guide Wear
1 ± VALVE
2 ± SPECIAL TOOL C-3339
REAMER SIZES CHART
REAMER O/S VALVE GUIDE SIZE
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 - 0.317 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) (0.328 - 0.329 in.)
DN5.2L ENGINE 9 - 121
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine REFACING VALVES AND VALVE SEATS
The intake and exhaust valves have a 43-1/4É to
43-3/4É face angle and a 44-1/4É to 44-3/4É seat angle
(Fig. 77).
VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 78). Valves with less than 1.190 mm
(0.047 inch) margin should be discarded.VALVE SEATS
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 79).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained.
Fig. 77 Valve Face and Seat Angles
1 ± CONTACT POINT
ITEM DESCRIPTION SPECIFICATION
ASEAT WIDTH - 1.016 - 1.524
mm
INTAKE (0.040 - 0.060
in.)
EXHAUST 1.524 - 2.032
mm
(0.060 - 0.080
in.)
BFACE ANGLE
(INT. AND
EXT.)43
1¤4É-433¤4É
CSEAT ANGLE
(INT. AND
EXT.)44
1¤4É-443¤4É
DCONTACT
SURFACE Ð
Fig. 78 Intake and Exhaust Valves
1 ± MARGIN
2 ± VALVE SPRING RETAINER LOCK GROOVE
3 ± STEM
4±FACE
Fig. 79 Refacing Valve Seats
1±STONE
2 ± PILOT
3 ± VALVE SEAT
4 ± SHROUD
9 - 122 5.2L ENGINEDN
DISASSEMBLY AND ASSEMBLY (Continued)

Downloaded from www.Manualslib.com manuals search engine (2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading.
(3) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with 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
Universals 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. 80).
Place spring over stud on the table and lift compress-
ing 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 mea-
surements are indicated on the table for finer adjust-
ments. Refer to specifications to obtain specified
height and allowable tensions. Discard the springs
that do not meet specifications.
OIL PUMP
DISASSEMBLE
(1) Remove the relief valve as follows:
(a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and
insert a self-threading sheet metal screw.
(b) Clamp screw into a vise and while support-
ing oil pump, remove cap by tapping pump body
using a soft hammer. Discard retainer cap and
remove spring and relief valve (Fig. 81).
(2) Remove oil pump cover (Fig. 82).
(3) Remove pump outer rotor and inner rotor with
shaft (Fig. 82).
(4) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
ASSEMBLE
(1) Install pump rotors and shaft, using new parts
as required.
(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N´m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling
rotor cavity with engine oil.
Fig. 80 Testing Valve Spring for Compressed
Length
1 ± TORQUE WRENCH
2 ± VALVE SPRING TESTER
Fig. 81 Oil Pressure Relief Valve
1 ± OIL PUMP ASSEMBLY
2 ± COTTER PIN
3 ± RELIEF VALVE
4 ± RETAINER CAP
5 ± SPRING
DN5.2L ENGINE 9 - 123
DISASSEMBLY AND ASSEMBLY (Continued)

Downloaded from www.Manualslib.com manuals search engine DESCRIPTION SPECIFICATION
Main Bearing Journal
Diameter 63.487 ± 63.513 mm
(2.4995 ± 2.5005 in.)
Out of Round (Max.) 0.127 mm
(0.001 in.)
Taper (Max.) 0.0254 mm
(0.001 in.)
Bearing Clearance
(#1 Journal) 0.013 ± 0.038 mm
(0.0005 ± 0.0015 in.)
(#2-5 Journals) 0.013 ± 0.051 mm
(0.0005 ± 0.002 in.)
Service Limit
(#1 Journal) 0.0381 mm
(0.0015 in.)
(#2-5 Journals) 0.064 mm
(0.0025 in.)
End Play 0.051 ± 0.178 mm
(0.002 ± 0.007 in.)
Service Limit 0.254 mm
(0.010 in.)
CYLINDER BLOCK
Cylinder Bore
Diameter 99.308 ± 99.371 mm
(3.9098 ± 3.9122 in.)
Out of Round (Max.) 0.025 mm
(0.001 in.)
Taper (Max.) 0.025 mm
(0.001 in.)
Oversize Limit 1.016 mm
(0.040 in.)
Lifter Bore Diameter 22.99 ± 23.01 mm
(0.9051 ± 0.9059 in.)
Distributor Drive Bushing
(Press Fit)
Bushing to Bore
Interference0.0127 ± 0.3556 mm
(0.0005 ± 0.0140 in.)
Shaft to Bushing
Clearance0.0178 ± 0.0686 mm
(0.0007 ± 0.0027 in.)DESCRIPTION SPECIFICATION
CYLINDER HEAD
Valve Seat
Angle 44.25É ± 44.75É
Runout (Max.) 0.0762 mm
(0.003 in.)
Width (Finish)
Intake 1.016 ± 1.524 mm
(0.040 ± 0.060 in.)
Exhaust 1.524 ± 2.032 mm
(0.060 ± 0.080 in.)
VA LV E S
Face Angle 43.25É ± 43.75É
Head Diameter
Intake 48.666 mm
(1.916 in.)
Exhaust 41.250 mm
(1.624 in.)
Length (Overall)
Intake 124.28 ± 125.92 mm
(4.893 ± 4.918 in.)
Exhaust 124.64 ± 125.27 mm
(4.907 ± 4.932 in.)
Lift (@ zero lash) 10.973 mm
(0.432 in.)
Stem Diameter 7.899 ± 7.925 mm
(0.311 ± 0.312 in.)
Guide Bore 7.950 ± 7.976 mm
(0.313 ± 0.314 in.)
Stem to Guide Clearance 0.0254 ± 0.0762 mm
(0.001 ± 0.003 in.)
Service Limit (rocking
method)0.4318 mm
(0.017 in.)
DN5.2L ENGINE 9 - 129
SPECIFICATIONS (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)

Downloaded from www.Manualslib.com manuals search engine Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise, the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs.
(3) Secure the throttle in the wide-open position.
(4) Disconnect the ignition coil.
(5) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(6) Record the compression pressure on the third
revolution. Continue the test for the remaining cylin-
ders.
Refer to Engine Specifications for the correct
engine compression pressures.
CYLINDER HEAD GASKET FAILURE DIAGNOSIS
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
²Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
²Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test in this
section. An engine cylinder head gasket leaking
between adjacent cylinders will result in approxi-
mately a 50±70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing)
²Leaks between adjacent cylinders or into water
jacket
²Any causes for combustion/compression pressure
loss
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM HOT COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn OFF the
engine.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
Perform the test procedure on each cylinder accord-
ing to the tester manufacturer's instructions. While
testing, listen for pressurized air escaping through
the throttle body, tailpipe or oil filler cap opening.
Check for bubbles in the radiator coolant.
9 - 146 5.9L ENGINEDN
DIAGNOSIS AND TESTING (Continued)

Downloaded from www.Manualslib.com manuals search engine HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor-
rect tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending-unit. The pressure should be
between 207-552 kPa (30-80 psi) at 3,000 RPM.
Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick. The oil level in the pan
should never be above the FULL mark or below the
ADD OIL mark on dipstick. Either of these two con-
ditions could be responsible for noisy tappets.
OIL LEVEL
HIGH
If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the
engine running, this condition could create foam in
the oil pan. Foam in oil pan would be fed to the
hydraulic tappets by the oil pump causing them to
lose length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to take in air.
When air is fed to the tappets, they lose length,
which allows valves to seat noisily. Any leaks on
intake side of oil pump through which air can be
drawn will create the same tappet action. Check the
lubrication system from the intake strainer to the
pump cover, including the relief valve retainer cap.
When tappet noise is due to aeration, it may be
intermittent or constant, and usually more than one
tappet will be noisy. When oil level and leaks have
been corrected, operate the engine at fast idle. Run
engine for a sufficient time to allow all of the air
inside the tappets to be bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate
engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy tappet will cause the affected
spring and/or rocker arm to vibrate or feel rough in
operation.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3) Valve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces-
sive leak-down around the unit plunger, or by theplunger partially sticking in the tappet body cylinder.
The tappet should be replaced. A heavy click is
caused by a tappet check valve not seating, or by for-
eign particles wedged between the plunger and the
tappet body. This will cause the plunger to stick in
the down position. This heavy click will be accompa-
nied by excessive clearance between the valve stem
and rocker arm as valve closes. In either case, tappet
assembly should be removed for inspection and clean-
ing.
(4) The valve train generates a noise very much
like a light tappet noise during normal operation.
Care must be taken to ensure that tappets are mak-
ing the noise. If more than one tappet seems to be
noisy, it's probably not the tappets.
LEAK-DOWN TEST
After cleaning and inspection, test each tappet for
specified leak-down rate tolerance to ensure zero-lash
operation (Fig. 11).
Swing the weighted arm of the hydraulic valve tap-
pet tester away from the ram of the Universal Leak-
Down Tester.
(1) Place a 7.925-7.950 mm (0.312-0.313 inch)
diameter ball bearing on the plunger cap of the tap-
pet.
(2) Lift the ram and position the tappet (with the
ball bearing) inside the tester cup.
(3) Lower the ram, then adjust the nose of the ram
until it contacts the ball bearing. DO NOT tighten
the hex nut on the ram.
(4) Fill the tester cup with hydraulic valve tappet
test oil until the tappet is completely submerged.
(5) Swing the weighted arm onto the push rod and
pump the tappet plunger up and down to remove air.
When the air bubbles cease, swing the weighted arm
away and allow the plunger to rise to the normal
position.
(6) Adjust the nose of the ram to align the pointer
with the SET mark on the scale of the tester and
tighten the hex nut.
(7) Slowly swing the weighted arm onto the push
rod.
(8) Rotate the cup by turning the handle at the
base of the tester clockwise one revolution every 2
seconds.
(9) Observe the leak-down time interval from the
instant the pointer aligns with the START mark on
the scale until the pointer aligns with the 0.125
mark. A normally functioning tappet will require
20-110 seconds to leak-down. Discard tappets with
leak-down time interval not within this specification.
ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit.
9 - 148 5.9L ENGINEDN
DIAGNOSIS AND TESTING (Continued)

Downloaded from www.Manualslib.com manuals search engine (2) With engine OFF, allow approximately ten min-
utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Install dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. This infor-
mation can be found in your owner's manual.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
tion.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
ENGINE OIL FILTER CHANGE
FILTER SPECIFICATION
All engines are equipped with a high quality full-
flow, disposable type oil filter. DaimlerChrysler Cor-
poration recommends a Mopar or equivalent oil filter
be used.
OIL FILTER REMOVAL
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss (Fig. 15).
(4) When filter separates from adapter nipple, tip
gasket end upward to minimize oil spill. Remove fil-
ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface (Fig. 16) of oil and grime.
OIL FILTER INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 16) hand
tighten filter one full turn, do not over tighten.
(3) Add oil, verify crankcase oil level and start
engine. Inspect for oil leaks.
REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Fig. 14 Engine Oil Dipstick LocationÐ5.9L Engines
1 ± CYLINDER HEAD COVER
2 ± ENGINE OIL FILL-HOLE CAP
3 ± DIPSTICK
4 ± ENGINE OIL FILTER
5 ± FILTER BOSS
Fig. 15 Oil Filter RemovalÐTypical
1 ± ENGINE OIL FILTER
2 ± OIL FILTER WRENCH
DN5.9L ENGINE 9 - 151
SERVICE PROCEDURES (Continued)