1999 DODGE DURANGO Exhaust

Downloaded from www.Manualslib.com manuals search engine (2)Install the dowels in the cylinder block (Fig. 64).
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 N´m (215 in. lbs.)
torque.(8) Install the drain plug. Tighten drain plug to 34
N´m (25 ft. lbs.) torque.
(9) Lower transmission onto crossmember.
(10) Install rear support cushion mounting bolts.
Tighten bolts to 28 N´m (250 in. lbs.).
(11) Raise engine by way of oil pan with a wood
block placed between jack and oil pan.
(12) Remove through bolts from frame brackets
and lower engine. Install mount insulator through
bolts and tighten to 95 N´m (70 ft. lbs.).
(13) Install starter.
(14) Install transmission torque converter inspec-
tion cover.
(15) Install engine to transmission braces.
(16) Install exhaust pipe.
(17) Lower vehicle.
(18) Position throttle valve cable into bracket, then
attach to throttle body (Fig. 62A).
(19) Connect the distributor cap.
(20) Install dipstick.
(21) Install fan shroud.
(22) Install air cleaner assembly.
(23) Connect the negative cable to the battery.
(24) Fill crankcase with oil to proper level.
4WD
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
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).
(2) Install the dowels in the cylinder block (Fig.
64).
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 N´m (215 in. lbs.)
torque.
(8) Install the drain plug. Tighten drain plug to 34
N´m (25 ft. lbs.) torque.
(9) Install transmission inspection cover.
(10) Install engine mount support brackets and
insulators.
(11) Install front drive axle. Refer to DIFFEREN-
TIAL and DRIVELINE.
(12) Lower vehicle.
(13) Connect the distributor cap.
(14) Install dipstick.
(15) Connect the negative cable to the battery.
(16) Fill crankcase with oil to proper level.
Fig. 63 Fabrication of Alignment Dowels
1 ± 1 1/2º x 5/16º BOLT
2 ± DOWEL
3 ± SLOT
Fig. 64 Position of Dowels in Cylinder Block
1 ± DOWEL
2 ± DOWEL
3 ± DOWEL
4 ± DOWEL
9 - 115A 5.2L ENGINEDN
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 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 CYLINDER BLOCK
DISASSEMBLE
With Engine removed from vehicle:
(1) Remove the cylinder heads. refer to Cylinder
Head in this section for correct procedure.
(2) Remove the exhaust manifolds. Refer to
Exhaust Manifolds in this section.
(3) Remove the oil pan. Refer to Oil Pan in this
section.
(4) Remove the piston and connecting rod assem-
blies. Refer to Piston and Connecting Rod in this sec-
tion.
(5) Remove the crankshaft. Refer to Crankshaft in
this section.
(6) Remove the core plugs.
ASSEMBLE
(1) Install the core plugs.
(2) Install the crankshaft.
(3) Install the piston and connecting rods.
(4) Install the oil pan.
(5) Install the cylinder heads.
(6) Install the exhaust manifolds.
(7) Install the intake manifold.
(8) Install the engine into the vehicle.
CLEANING AND INSPECTION
CYLINDER HEAD COVER
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
CYLINDER HEAD ASSEMBLY
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness
exceeds 0.00075 mm/mm (0.00075 inch/inch) times
the span length in inches in any direction, either
replace head or lightly machine the head surface.
FOR EXAMPLE:A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 X 0.00075 (12 X 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept-
able.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
PISTON AND CONNECTING ROD ASSEMBLY
INSPECTION
Check the crankshaft connecting rod journal for
excessive wear, taper and scoring.
Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
Check the pistons for taper and elliptical shape
before they are fitted into the cylinder bore (Fig. 83).
OIL PAN
CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove.DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
engine.
Fig. 82 Oil Pump
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 - 124 5.2L ENGINEDN
DISASSEMBLY AND ASSEMBLY (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 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 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 TORQUE SPECIFICATIONS
TORQUE CHART 5.2L ENGINE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 50 Ð
Camshaft Thrust PlateÐBolts 24 Ð 210
Chain Case CoverÐBolts 41 30 Ð
Connecting Rod CapÐBolts 61 45 Ð
Main Bearing CapÐBolts 115 85 Ð
Crankshaft PulleyÐBolts 24 Ð 210
Cylinder HeadÐBolts
Step 1 68 50 Ð
Step 2 143 105 Ð
Cylinder Head CoverÐBolts 11 Ð 95
Engine Support Bracket to
BlockÐ41 30 Ð
Bolts (4WD)
Exhaust Manifold to Cylinder
HeadÐ34 25 Ð
Bolts/Nuts
FlywheelÐBolts 75 55 Ð
Front InsulatorÐThrough
bolt/nut95 70 Ð
Front Insulator to Support
BracketÐ
Stud Nut (4WD) 41 30 Ð
Through Bolt/Nut 102 75 Ð
Front Insulator to BlockÐ 95 70 Ð
Bolts (2WD)
GeneratorÐMounting Bolts 41 30 Ð
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 Ð 215
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐMounting Bolts 41 30 Ð
Oil Pump CoverÐBolts 11 Ð 95
Rear Insulator to BracketÐ
Through68 50 Ð
Bolt (2WD)
Rear Insulator to
Crossmember41 30 Ð
Support BracketÐNut (2WD)
Rear Insulator to
CrossmemberÐ68 50 Ð
Nuts (4WD)
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Rear Insulator to
TransmissionÐ68 50 Ð
Bolts (4WD)
Rear Insulator BracketÐBolts 68 50 Ð
(4WD Automatic)
Rear Support Plate to
Transfer Case41 30 Ð
ÐBolts
Rocker ArmÐBolts 28 21 Ð
Spark Plugs 41 30 Ð
Starter MotorÐMounting
Bolts68 50 Ð
Thermostat HousingÐBolts 25 Ð 225
Throttle BodyÐBolts 23 Ð 200
Torque Converter Drive
PlateÐBolts31 Ð 270
Transfer Case to Insulator
Mounting204 150 Ð
PlateÐNuts
Transmission Support
BracketÐ68 50 Ð
Bolts (2WD)
Vibration DamperÐBolt 183 135 Ð
Water Pump to Timing Chain
Case41 30 Ð
CoverÐBolts
SPECIAL TOOLS
5.2L ENGINE
Oil Pressure Gauge C-3292
9 - 132 5.2L ENGINEDN
SPECIFICATIONS (Continued)