2000 DODGE DURANGO Shaft

Downloaded from www.Manualslib.com manuals search engine (3) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith 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
Universal 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. 22). Place
spring over stud on the table and lift compressing
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 measurements
are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
meet specifications.
MEASURING TIMING CHAIN STRETCH
NOTE: To access timing chain Refer to Timing
Chain Cover in Removal and Installation Section.
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N´m (30 ft. lbs.) torque with cylinder head installed
or 20 N´m (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaft
Fig. 20 Intake and Exhaust Valves
1 ± MARGIN
2 ± VALVE SPRING RETAINER LOCK GROOVE
3 ± STEM
4±FACE
Fig. 21 Refacing Valve Seats
1±STONE
2 ± PILOT
3 ± VALVE SEAT
4 ± SHROUD
Fig. 22 Testing Valve Spring for Compressed
Length
1 ± TORQUE WRENCH
2 ± VALVE SPRING TESTER
DN5.2L ENGINE 9 - 97
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 23).
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
(5) If chain is not satisfactory, remove camshaft
sprocket attaching bolt and remove timing chain with
crankshaft and camshaft sprockets.
(6) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(7) Place timing chain around both sprockets.
(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(10) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 24).
(11) Install the camshaft bolt. Tighten the bolt to
47 N´m (35 ft. lbs.) torque.
(12) 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.
PISTONSÐFITTING
Piston and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylin-
der wall is 0.013-0.038 mm (0.0005-0.0015 inch) at
21ÉC (70ÉF).Piston diameter should be measured at the top of
skirt, 90É to piston pin axis. Cylinder bores should be
measured halfway down the cylinder bore and trans-
verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
Check the pistons for taper and elliptical shape
before they are fitted into the cylinder bore (Fig. 25).
PISTON RINGSÐFITTING
(1) Measurement of end gaps:
(a) Measure piston ring gap 2 inches from bot-
tom of cylinder bore. An inverted piston can be
used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measur-
ing.
(b) Insert feeler gauge in the gap. The top com-
pression ring gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compression
Fig. 23 Measuring Timing Chain Wear and Stretch
1 ± TORQUE WRENCH
2 ± 3.175 MM
(0.125 IN.)
Fig. 24 Alignment of Timing Marks
1 ± TIMING MARKS
Fig. 25 Piston Measurements
1 ± 49.53 mm
(1.95 IN.)
9 - 98 5.2L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine CONNECTING ROD BEARINGSÐFITTING
Fit all rods on a bank until completed. DO NOT
alternate from one bank to another, because connect-
ing rods and pistons are not interchangeable from
one bank to another.
The bearing caps are not interchangeable and
should be marked at removal to ensure correct
assembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing shell,
make certain that the V-groove in the shell is in line
with the V-groove in the cap. This provides lubrica-
tion of the cylinder wall in the opposite bank.The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
caps.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 inch).
Bearings are available in 0.025 mm (0.001 inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under-
size.Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing half. DO
NOT file the rods or bearing caps.
CRANKSHAFT MAIN BEARINGSÐFITTING
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter-
changeable. Lower main bearing halves of No.2 and 4
are interchangeable.
Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT
interchangeable with any other bearing halves in the
engine (Fig. 30). Bearing shells are available in stan-
dard and the following undersizes: 0.25 mm (0.001
inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
Never install an undersize bearing that will reduce
clearance below specifications.
REMOVAL AND INSTALLATION
ENGINE MOUNTSÐFRONT
REMOVAL
On 4WD vehicles the engine front support brackets
attach directly to engine block and the axle housing.
The brackets provide a solid interconnection for these
units (Fig. 31) (Fig. 32). Engine must be supported
during any service procedures involving the front
support assemblies.
Fig. 28 Compression Ring Chamfer Location
(Typical)
1 ± CHAMFER
2 ± TOP COMPRESSION RING
3 ± SECOND COMPRESSION RING
4 ± PISTON
5 ± CHAMFER
Fig. 29 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
Fig. 30 Main Bearing Identification
9 - 100 5.2L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine (2) Position the cylinder head cover onto the gas-
ket. Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4) Install the air inlet hose.
(5) Connect the negative cable to the battery.
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Remove cylinder head cover and gasket. Refer
to Cylinder Head Cover in this section for correct
procedure.
(2) Remove the rocker arm bolts and pivots (Fig.
44). Place them on a bench in the same order as
removed.
(3) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
(1) Rotate the crankshaft until the ªV8º mark lines
up with the TDC mark on the timing chain case
cover. This mark is located 147É ATDC from the No.1
firing position.
(2) Install the push rods in the same order as
removed.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 N´m (21 ft. lbs.) torque.
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(4) Install cylinder head cover.
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE
(1) Remove the air cleaner.
(2) Remove cylinder head covers and spark plugs.(3) Remove coil wire from distributor and secure to
good ground to prevent engine from starting.
(4) Using suitable socket and flex handle at crank-
shaft retaining bolt, turn engine so the No.1 piston is
at TDC on the compression stroke.
(5) Remove rocker arms.
(6) With air hose attached to an adapter installed
in No.1 spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.
(7) Using Valve Spring Compressor Tool
MD-998772A with adaptor 6716A, compress valve
spring and remove retainer valve locks and valve
spring.
(8) Install seals on the exhaust valve stem and
position down against valve guides.
(9) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as a guide. DO NOT force seal against top
of guide. When installing the valve retainer locks,
compress the spring only enough to install the locks.
(10) Follow the same procedure on the remaining 7
cylinders using the firing sequence 1-8-4-3-6-5-7-2.
Make sure piston in cylinder is at TDC on the valve
spring that is being removed.
(11) Remove adapter from the No.1 spark plug
hole and install spark plugs.
(12) Install rocker arms.
(13) Install covers and coil wire to distributor.
(14) Install air cleaner.
(15) Road test vehicle.
CYLINDER HEAD
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system Refer to COOLING SYS-
TEM.
(3) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(4) Remove closed crankcase ventilation system.
(5) Disconnect the evaporation control system.
(6) Remove the air cleaner assembly and air inlet
hose.
(7) Perform fuel system pressure release proce-
dure. Refer to FUEL SYSTEM.
(8) Disconnect the fuel supply line.
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect heat indicator sending unit wire.
(13) Disconnect heater hoses and bypass hose.
(14) Remove cylinder head covers and gaskets.
Fig. 44 Rocker Arms
1 ± ROCKER ARMS
2 ± CYLINDER HEAD
DN5.2L ENGINE 9 - 107
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine spring seat in cylinder head to the bottom surface of
spring retainer. If spacers are installed, measure
from the top of spacer. If height is greater than 42.86
mm (1-11/16 inches), install a 1.587 mm (1/16 inch)
spacer in head counterbore. This should bring spring
height back to normal 41.27 to 42.86 mm (1-5/8 to
1-11/16 inch).
HYDRAULIC TAPPETS
REMOVAL
(1) Remove the air cleaner assembly and air inlet
hose.
(2) Remove cylinder head cover, rocker assembly
and push rods. Identify push rods to ensure installa-
tion in original location.
(3) Remove intake manifold, yoke retainer and
aligning yokes.
(4) Slide Hydraulic Tappet Remover/Installer Tool
C-4129-A through opening in cylinder head and seat
tool firmly in the head of tappet.
(5) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed, identify tappets to
ensure installation in original location.
INSTALLATION
(1) If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet.
(2) Lubricate tappets.
(3) Install tappets and push rods in their original
positions. Ensure that the oil feed hole in the side of
the tappet body faces up (away from the crankshaft).
(4) Install aligning yokes with ARROW toward
camshaft.
(5) Install yoke retainer. Tighten the bolts to 23
N´m (200 in. lbs.) torque. Install intake manifold.
(6) Install push rods in original positions.
(7) Install rocker arm.
(8) Install cylinder head cover.
(9) Install air cleaner assembly and air inlet hose.
(10) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
VIBRATION DAMPER
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine.(3) Remove the cooling system fan.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove the vibration damper pulley.
(6) Remove vibration damper bolt and washer from
end of crankshaft.
(7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 46).
(8) Pull vibration damper off of the crankshaft.
INSTALLATION
(1) Position the vibration damper onto the crank-
shaft.
(2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 47).
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 183 N´m (135 ft. lbs.) torque.
(4) Install the crankshaft pulley. Tighten the pul-
ley bolts to 23 N´m (200 in. lbs.) torque.
(5) Install the serpentine belt (refer to Group 7,
Cooling System).
(6) Install the cooling system fan. Tighten the
bolts to 23 N´m (17 ft. lbs.) torque.
Fig. 46 Vibration Damper Assembly
1 ± SPECIAL TOOL C-3688
Fig. 47 Installing Vibration Damper
1 ± SPECIAL TOOL C-3688
DN5.2L ENGINE 9 - 109
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (7) Position the fan shroud and install the bolts.
Tighten the retainer bolts to 11 N´m (95 in. lbs.)
torque.
(8) Connect the negative cable to the battery.
TIMING CHAIN COVER
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (refer to Group 7, Cooling
System).
(3) Remove the serpentine belt (refer to Group 7,
Cooling System).
(4) Remove water pump (refer to Group 7, Cooling
System).
(5) Remove power steering pump (refer to Group
19, Steering).
(6) Remove vibration damper.
(7) Remove fuel lines (refer to Group 14, Fuel Sys-
tem).
(8) Loosen oil pan bolts and remove the front bolt
at each side.
(9) Remove the cover bolts.
(10) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
(11) 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 surface of cover (Fig. 48).
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) The water pump mounting surface must be
cleaned.
(3) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar Silicone Rubber Adhe-
sive Sealant, or equivalent, at the joint between tim-
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.
(4) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 49). Seat
the oil seal in the groove of the tool.
(5) Position the seal and tool onto the crankshaft
(Fig. 50).(6) Tighten the 4 lower chain case cover bolts to
13N´m (10 ft.lbs.) to prevent the cover from tipping
during seal installation.
(7) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 51).
(8) Loosen the 4 bolts tightened in step 4 to allow
realignment of front cover assembly.
Fig. 48 Removal of Front Crankshaft Oil Seal
Fig. 49 Placing Oil Seal on Installation Tool 6635
1 ± CRANKSHAFT FRONT OIL SEAL
2 ± INSTALL THIS END INTO SPECIAL TOOL 6635
Fig. 50 Position Tool and Seal onto Crankshaft
1 ± SPECIAL TOOL 6635
2 ± OIL SEAL
3 ± TIMING CHAIN COVER
9 - 110 5.2L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

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 (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)