2000 DODGE DURANGO Transmission

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
(1) Clean Gasket Maker residue and sealant from
the cylinder block and rear cap mating surface. Do
this before applying the MopartGasket Maker and
the installation of rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of MopartGasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 66). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.
(8) To align the bearing cap, use cap slot, align-
ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 N´m (85 ft. lbs.) torque.
(10) Install oil pump.
(11) Install the timing chain cover.
(12) Install the vibration damper.
(13) Position the connecting rods onto the crank-
shaft and install the rod bearing caps. Tighten the
nuts to 61 N´m (45 ft. lbs.).
(14) Apply MopartSilicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 67).Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(15) Install new front crankshaft oil seal.
(16) Immediately install the oil pan.
(17) If the transmission was removed, install the
transmission.
OIL PUMP
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from rear main bearing
cap.
INSTALLATION
(1) Install oil pump. During installation slowly
rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold the oil pump base flush against mating
surface on No.5 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
N´m (30 ft. lbs.) torque.
(3) Install the oil pan.
CRANKSHAFT OIL SEALÐFRONT
The oil seal can be replaced without removing the
timing chain cover provided the cover is not mis-
aligned.
(1) Disconnect the negative cable from the battery.
(2) Remove vibration damper.
(3) If front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa-
tion/alignment tool 6635, should fit with minimum
Fig. 66 Sealant Application to Bearing Cap
1 ± .25 DROP OF LOCTITE 515 ON BOTH SIDES OF REAR
MAIN CAP
Fig. 67 Apply Sealant to Bearing Cap to Block Joint
1 ± MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE
TIP
2 ± SEALANT APPLIED
3 ± CYLINDER BLOCK
4 ± REAR MAIN BEARING CAP
DN5.2L ENGINE 9 - 117
REMOVAL AND INSTALLATION (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)

Downloaded from www.Manualslib.com manuals search engine Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
CYLINDER BOREÐHONING
Before honing, stuff plenty of clean shop towels
under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.The hone marks should INTERSECT at 50É to 60É
for proper seating of rings (Fig. 17).
(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50É to 60É
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
HYDROSTATIC LOCK
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure
(refer to Group 14, Fuel System).
(2) Disconnect the battery negative cable.
(3) Inspect air cleaner, induction system and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the plugs from the
engine.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
Fig. 16 Oil Filter Sealing SurfaceÐTypical
1 ± SEALING SURFACE
2 ± RUBBER GASKET
3 ± OIL FILTER
Fig. 17 Cylinder Bore Crosshatch Pattern
1 ± CROSSHATCH PATTERN
2 ± INTERSECT ANGLE
9 - 152 5.9L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine REMOVALÐ4WD
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. 35) (Fig. 36). Engine must be supported
during any service procedures involving the front
support assemblies.
(1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist.
(3) Install engine lifting (support) fixture.
(4) Remove front axle. (Refer to Group 3, Differen-
tial and Driveline in this publication.)
(5)Left mount insulator only.Remove starter
wires and starter motor assembly.
(6) Remove insulator to frame through bolt (Fig.
37).
(7) Raise engine slightly.
(8) Remove upper insulator to support bracket
stud nut and insulator to support through bolt.
(9) Remove engine mount insulator (Fig. 35) (Fig.
36).
(10) If engine support bracket is to be removed/re-
placed, remove support bracket to transmission bell
housing bolt(s) and three (3) support bracket to
engine block bolts. Remove support bracket (Fig. 35)
(Fig. 36).
Fig. 32 Engine Right Front Insulator MountÐ2WD
Vehicles
1 ± HEAT SHIELD
2 ± INSULATOR
Fig. 33 Engine Left Front Insulator MountÐ2WD
Vehicles
1 ± HEAT SHIELD
2 ± INSULATOR
Fig. 34 Engine Mount Insulator at Frame
1 ± NUT
2 ± INSULATOR
3 ± FRAME
4 ± THROUGH BOLT
DN5.9L ENGINE 9 - 159
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSTALLATIONÐ4WD
(1) If engine support brackets were removed,
install them and their fasteners (Fig. 35) (Fig. 36).
Tighten support bracket to block bolts to 41 N´m (30
ft. lbs.). Tighten support bracket to transmission bell-
housing bolt(s) to 88 N´m (65 ft. lbs.).
(2) Install Engine mount insulator and tighten
insulator to support bracket nut to 41 N´m (30 ft.
lbs.). Tighten insulator to support bracket through
bolt nut to 102 N´m (75 ft. lbs.).
(3) Lower engine and install insulator to frame
through bolt and nut (Fig. 37). Tighten nut to 95 N´m
(70 ft. lbs.).
(4) Install starter motor and mounting bolts.
Tighten bolts to 68 N´m (50 ft. lbs.).
(5) Connect starter wires.
(6) Remove engine lifting (support) fixture.
(7) Install front axle assembly (Refer to Group 3,
Differential and Driveline).
(8) Lower the vehicle.
(9) Connect the negative cable to the battery.
ENGINE REAR SUPPORT
REMOVALÐ2WD
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Support the transmission with a jack.
(4) Remove engine support bracket and insulator
thru-bolt (Fig. 38).
(5) Raise the transmission and engine slightly.
(6) Remove stud nuts attaching insulator to cross-
member (Fig. 38). Remove insulator.
INSTALLATIONÐ2WD
(1) If the engine support bracket was removed,
position the bracket to the transmission extension
(Fig. 38). Tighten the bolts to 68 N´m (50 ft. lbs.)
torque.
(2) Install the insulator onto crossmember. Tighten
the stud nuts to 41 N´m (30 ft. lbs) torque.
(3) Lower the transmission and engine while align-
ing the engine support bracket to the insulator.
(4) Install thru-bolt in bracket and insulator.
Tighten thru-bolt nut to 68 N´m (50 ft. lbs.) torque.
(5) Remove transmission jack.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
Fig. 35 Right Engine Mount Insulator and Support
BracketÐ4WD Vehicles
1 ± ENGINE SUPPORT BRACKET
2 ± INSULATOR
3 ± FRONT AXLE
Fig. 36 Left Engine Mount Insulator and Support
BracketÐ4WD Vehicles
1 ± ENGINE SUPPORT BRACKET
2 ± INSULATOR
3 ± FRONT AXLE
9 - 160 5.9L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine REMOVALÐ4WD
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Support the transmission with a transmission
jack.
(4) Remove stud nuts holding the insulator to the
crossmember (Fig. 39).
(5) Raise rear of transmission SLIGHTLY.
(6) Remove bolts holding the insulator to the insu-
lator bracket (Fig. 39). Remove the insulator.
INSTALLATIONÐ4WD
(1) If the insulator bracket was removed, install
the bracket to the transmission (Fig. 39). Tighten the
bolts to 28 N´m (250 in. lbs.) torque.
(2) Install the bolts holding insulator to insulator
bracket. Tighten the bolts to 28 N´m (250 in. lbs.)
torque.
(3) Lower rear of transmission while aligning the
insulator studs into the mounting support bracket.Install stud nuts and tighten to 28 N´m (250 in. lbs.)
torque.
(4) Remove the transmission jack.
(5) Lower the vehicle.
(6) Connect the negative cable to the battery.
ENGINE ASSEMBLY
REMOVAL
(1) Scribe hood hinge outlines on hood. Remove the
hood.
(2) Remove the battery.
(3) Drain cooling system. Refer to COOLING SYS-
TEM.
(4) Remove the air cleaner assembly and air inlet
hose.
(5) Disconnect the radiator and heater hoses.
(6) Set fan shroud aside.
(7) Remove the vacuum lines.
(8) Remove the distributor cap and wiring.
(9) Disconnect the accelerator linkage.
(10) Remove throttle body.
(11) Perform the Fuel System Pressure release
procedure Refer to FUEL SYSTEM.
(12) Disconnect the fuel lines.
(13) Disconnect the starter wires.
(14) Disconnect the oil pressure wire.
Fig. 37 Engine Mount Insulator at FrameÐ4WD
Vehicles
1 ± NUT
2 ± ENGINE SUPPORT BRACKET
3 ± INSULATOR
4 ± NUT
5 ± THROUGH BOLT
6 ± FRAME
7 ± FRONT AXLE
Fig. 38 Rear InsulatorÐ2WD Vehicles
1 ± ENGINE SUPPORT BRACKET
2 ± THROUGH BOLT
3 ± CROSSMEMBER
4 ± INSULATOR
5 ± TRANSMISSION EXTENSION
DN5.9L ENGINE 9 - 161
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (15) Discharge the air conditioning system, if
equipped. Refer to HEATING and AIR CONDITION-
ING.
(16) Disconnect the air conditioning hoses.
(17) Disconnect the power steering hoses, if
equipped.
(18) Remove starter motor. Refer to STARTING
SYSTEMS.
(19) Remove the generator.
(20) Raise and support the vehicle on a hoist.
(21) Disconnect exhaust pipe at manifold.
(22) Remove Transmission. Refer to TRANSMIS-
SIONS.
CAUTION: DO NOT lift the engine by the intake
manifold.
(23) Install an engine lifting fixture.
(24)2WD VEHICLESÐRemove engine front
mount bolts.
(25)4WD VEHICLESÐThe engine and front
driving axle (engine/axle/transmission) are connectedthrough insulators and support brackets. Separate
the engine as follows:
²LEFT SIDEÐRemove 2 bolts attaching
(engine/pinion nose/transmission) bracket to trans-
mission bell housing. Remove 2 bracket to pinion
nose adaptor bolts. Separate engine from insulator by
removing upper nut washer assembly and bolt from
engine support bracket.
²RIGHT SIDEÐRemove 2 bracket to axle (dis-
connect housing) bolts and a bracket to bell housing
bolt. Separate engine from insulator by removing
upper nut washer assembly and bolt from engine
support bracket.
(26) Lower the vehicle.
(27) Install engine assembly on engine repair
stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Install the engine front mounts.
(5) Refer to Group, 21 Transmissions for transmis-
sion installation
(6) Install the inspection plate.
(7) Remove transmission support.
(8) Install exhaust pipe to manifold.
(9) Lower the vehicle.
(10) Remove engine lifting fixture.
(11) Install the generator.
(12) Install starter motor.
(13) Connect power steering hoses, if equipped.
(14) Connect air conditioning hoses.
(15) Evacuate and charge the air conditioning sys-
tem, if equipped.
(16) Using a new gasket, install throttle body.
Tighten the throttle body bolts to 23 N´m (200 in.
lbs.) torque.
(17) Connect the accelerator linkage.
(18) Connect the starter wires.
(19) Connect the oil pressure wire.
(20) Install the distributor cap and wiring.
(21) Connect the vacuum lines.
(22) Connect the fuel lines.
(23) Install the radiator. Connect the radiator
hoses and heater hoses.
(24) Install fan shroud in position.
(25) Fill cooling system.
(26) Install the air cleaner assembly and air inlet
hose.
(27) Install the battery.
(28) Warm engine and adjust.
(29) Install hood and line up with the scribe
marks.
(30) Road test vehicle.
Fig. 39 Rear InsulatorÐ4WD Vehicles
1 ± AUTOMATIC TRANSMISSION
2 ± INSULATOR BRACKET
3 ± INSULATOR
4 ± CROSSMEMBER
9 - 162 5.9L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain the cooling system. Refer to COOLING
SYSTEM.
(3) Remove the A/C compressor. Refer to HEAT-
ING and AIR CONDITIONING.
(4) Remove the generator. Refer to CHARGING
SYSTEM.
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner assembly and air inlet
hose.
(7) Perform the fuel pressure release procedure.
Refer to FUEL SYSTEM.
(8) Disconnect the fuel supply line from the fuel
rail. Refer to FUEL SYSTEM.
(9) Disconnect the accelerator linkage and, if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the coolant temperature sending
unit wire.
(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 40). Dis-
card the throttle body gasket.
INSTALLATION
(1) If the plenum pan was removed, position pan
gasket and pan.
(2) Install plenum pan retaining bolts. (Fig. 41).
(3) Tighten plenum pan mounting bolts as follows:
²Step 1. Tighten bolts to 5.4 N´m (24 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check all bolts are at 9.5 N´m (84 in.
lbs.)
(4) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N´m
(200 in. lbs.) torque.
(5) Apply a bead of Mopar Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
The sealant bead height should be slightly higher
than the cross-over gaskets, approximately 5 mm (0.2
in). An excessive amount of sealant is not required to
ensure a leak proof seal, and an excessive amount of
sealant may reduce the effectiveness of the flange
gasket.
(6) Install the front and rear cross-over gaskets
onto the engine (Fig. 42).
(7) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 43). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(8) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. long studs
at the front and rear of the manifold will help to
align the intake manifold. After intake manifold is in
Fig. 40 Throttle Body Assembly
1 ± FUEL RAIL ASSEMBLY
2 ± FUEL RAIL MOUNTING BOLTS
3 ± FUEL RAIL CONNECTING HOSES
Fig. 41 Plenum Pan Bolt Tightening Sequence
DN5.9L ENGINE 9 - 163
REMOVAL AND INSTALLATION (Continued)