2000 DODGE DURANGO drain bolt

Downloaded from www.Manualslib.com manuals search engine ENGINE LUBRICATION FLOW CHARTÐCYLINDER HEADS: TABLE 2
FROM TO
Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery
Main Oil Gallery (drilled through head from rear to front)1. Base of Camshaft Towers
2. Lash Adjuster Towers
Base of Camshaft Towers Vertical Drilling Through Tower to Camshaft Bearings**
Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets
** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
lobes, which have oil passages drilled into them to lubricate the rocker arms.
CYLINDER BLOCK
DESCRIPTION
The cylinder block is made of cast iron. The block
is a closed deck design with the left bank forward. To
provide high rigidity and improved NVH an
enhanced compacted graphite bedplate is bolted to
the block. The block design allows coolant flow
between the cylinders bores, and an internal coolant
bypass to a single poppet inlet thermostat is included
in the cast aluminum front cover.
CRANKSHAFT
DESCRIPTION
The crankshaft is constructed of nodular cast iron.
The crankshaft is a crosshaped four throw design
with eight counterweights for balancing purposes.
The crankshaft is supported by five select main bear-
ings with the number three serving as the thrust
washer location. The main journals of the crankshaft
are cross drilled to improve rod bearing lubrication.
The number eight counterweight has provisions for
crankshaft position sensor target wheel mounting.
The select fit main bearing markings are located on
the rear side of the target wheel. The crankshaft oil
seals are one piece design. The front oil seal is
retained in the timing chain cover, and the rear seal
is pressed in to a bore formed by the cylinder block
and the bedplate assembly.
PISTON AND CONNECTING ROD
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.
EARLY BUILD
The pistons are made of a high strength aluminum
alloy with an anodized top ring groove and crown. Piston
skirts are coated with a solid lubricant (Molykote) to
reduce friction and provide scuff resistance. The connect-
ing rods are made of forged powdered metal, with a
ªfractured capº design. A pressed fit piston pin is used to
attach the piston and connecting rod.
LATE BUILD
The pistons are made of high strength aluminum
alloy. The top ring groove and crown areNotanod-
ized, instead the top ring is coated with an anti-scuff
coating to reduce friction on the top ring. The piston
skirts are coated with a solid lubricant (Molykote) to
reduce friction and provide scuff resistance. The con-
necting rods are made of forged powdered metal,
with a ªfractured capº design. A pressed fit piston pin
is used to attach the piston and connecting rod.
CYLINDER HEAD
DESCRIPTION
The cylinder heads are made of an aluminum alloy.
The cylinder head features two valves per cylinder
with pressed in powdered metal valve guides. The
cylinder heads also provide enclosures for the timing
chain drain, necessitating unique left and right cylin-
der heads.
VALVE GUIDES
DESCRIPTION
The valve guides are made of powered metal and
are pressed into the cylinder head. The guides are
not replaceable or serviceable, and valve guide ream-
ing is not recommended. If the guides are worn
beyond acceptable limits, replace the cylinder heads.
VALVES
DESCRIPTION
The valves are made of heat resistant steel and
have chrome plated stems to prevent scuffing. Each
valve is actuated by a roller rocker arm which pivots
on a stationary lash adjuster. All valves use three
bead lock keepers to retain the springs and promote
valve rotation.
VALVE STEM SEAL
DESCRIPTION
The valve stem seals are made of rubber and incor-
porate an integral steel valve spring seat. The inte-
gral garter spring maintains consistent lubrication
control to the valve stems.
DN4.7L ENGINE 9 - 5
DESCRIPTION AND OPERATION (Continued)
2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99 December, 1999

Downloaded from www.Manualslib.com manuals search engine ENGINE ASSEMBLY
REMOVAL
NOTE: This procedure applies to both the 4X2 and
4X4 vehicles, steps that apply to the 4X4 vehicle
only, are identified.
(1) Disconnect the battery negative and positive
cables.
(2) Remove the battery and the battery tray. Refer
to BATTERY.
(3) Raise vehicle on hoist.
(4) Remove exhaust crossover pipe from exhaust
manifolds. Refer to EXHAUST SYSTEM.
(5)4X4 vehiclesDisconnect axle vent tube from
left side engine mount.
(6) Remove the through bolt retaining nut and bolt
from both the left and right side engine mounts (Fig.
40) (Fig. 41).
(7)4X4 vehiclesRemove locknut from left and
right side engine mount brackets (Fig. 41).
(8) Disconnect two ground straps from the lower
left hand side and one ground strap from the lower
right hand side of the engine.
(9) Disconnect crankshaft position sensor. (Fig. 43)
NOTE: The following step applies to 4X4 vehicles
equipped with automatic transmission only.
(10)4X4 vehiclesRemove the axle isolator
bracket from the engine, transmission and the axle
(Fig. 42).
(11) Remove structural cover. Refer to Structural
Cover in this section for procedure.
(12) Remove starter. Refer to STARTING SYS-
TEM.
(13) Drain cooling system. Refer to COOLING
SYSTEM.
(14) Remove torque converter bolts (Automatic
Transmission Only). Refer to TRANSMISSION.
(15) Remove transmission to engine mounting
bolts.
(16) Disconnect the engine block heater power
cable from the block heater, if equipped.(17) Lower vehicle.
(18) Remove throttle body resonator assembly and
air inlet hose.
(19) Disconnect throttle and speed control cables.
(20) Disconnect tube from both the left and right
side crankcase breathers (Fig. 44). Remove breathers
(21) Discharge A/C system. Refer to HEATING and
AIR CONDITIONING.
(22) Remove A/C compressor.
(23) Remove shroud, fan assemblies and accessory
drive belt. Refer to COOLING SYSTEM.
(24) Disconnect transmission oil cooler lines at the
radiator.
(25) Disconnect radiator upper and lower hoses.
Refer to COOLING SYSTEM.
(26) Remove radiator, A/C condenser and transmis-
sion oil cooler as an assembly. Refer to COOLING
SYSTEM.
(27) Remove generator.
(28) Disconnect the two heater hoses from the tim-
ing chain cover and heater core.
(29) Unclip and remove heater hoses and tubes
from the intake manifold (Fig. 45).
(30) Disconnect engine harness at the following
points :
²Intake air temperature (IAT) sensor (Fig. 46)
²Fuel Injectors
SEQUENCE ITEM TORQUE
1BOLT 54 N´m
(Qty 4) (40 ft. lbs.)
2BOLT 54 N´m
(Qty 2) (40 ft. lbs.)
3BOLT 54 N´m
(Qty 2) (40 ft. lbs.)
Fig. 40 Engine Mount Through Bolt and Nut
Removal / InstallationÐ4X2 Vehicles
1 ± LOCKNUT AND WASHER
2 ± ENGINE MOUNT/INSULATOR
3 ± THROUGH BOLT
4 ± FRAME
DN4.7L ENGINE 9 - 31
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INTAKE MANIFOLD
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove resonator assembly and air inlet hose.
(3) Disconnect throttle and speed control cables.
(4) Disconnect electrical connectors for the follow-
ing components: Refer to FUEL SYSTEM for compo-
nent locations.
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
(5) Disconnect vapor purge hose, brake booster
hose, speed control servo hose, positive crankcase
ventilation (PCV) hose.
(6) Disconnect generator electrical connections.
(7) Disconnect air conditioning compressor electri-
cal connections.
(8) Disconnect left and right radio suppressor
straps.
(9) Disconnect and remove ignition coil towers.
(10) Remove top oil dipstick tube retaining bolt
and ground strap.
(11) Bleed fuel system. Refer to FUEL SYSTEM.
(12) Remove fuel rail.
(13) Remove throttle body assembly and mounting
bracket.
(14) Drain cooling system below coolant tempera-
ture level. Refer to COOLING SYSTEM.
(15) Remove the heater hoses from the engine
front cover and the heater core.
(16) Unclip and remove heater hoses and tubes
from intake manifold (Fig. 50).
(17) Remove coolant temperature sensor. Refer to
FUEL SYSTEM.
(18) Remove intake manifold retaining fasteners in
reverse order of tightening sequence (Fig. 51).
(19) Remove intake manifold.
INSTALLATION
(1) Install intake manifold gaskets.
(2) Install intake manifold.
(3) Install intake manifold retaining bolts and
tighten in sequence shown in (Fig. 51) to 12 N´m
(105 in. lbs.).
(4) Install left and right radio suppressor straps.
(5) Install throttle body assembly.
(6) Install throttle cable bracket.
(7) Connect throttle cable and speed control cable
to throttle body.
(8) Install fuel rail.
(9) Install ignition coil towers.
Fig. 48 Body Ground StrapÐRight Side Removal /
Installation
1 ± NUT
2 ± A/C ACCUMULATOR
3 ± GROUND STRAP
Fig. 49 Body Ground StrapÐLeft Side Removal /
Installation
1 ± NUT
2 ± GROUND STRAP
3 ± BRAKE BOOSTER
DN4.7L ENGINE 9 - 35
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (10) Position and install heater hoses and tubes
onto intake manifold.
(11) Install the heater hoses to the heater core and
engine front cover.(12) Connect electrical connectors for the following
components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
²Ignition coil towers
²Fuel injectors
(13) Install top oil dipstick tube retaining bolt and
ground strap.
(14) Connect generator electrical connections.
(15) Connect Vapor purge hose, Brake booster
hose, Speed control servo hose, Positive crankcase
ventilation (PCV) hose.
(16) Fill cooling system.
(17) Install resonator assembly and air inlet hose.
(18) Connect negative cable to battery.
EXHAUST MANIFOLDS
RIGHT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable for battery.
(2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
(3) Remove accessory drive belt. Refer to COOL-
ING SYSTEM.
(4) Remove A/C compressor from mounting and set
aside.
(5) Remove A/C accumulator support bracket fas-
tener.
(6) Drain coolant below heater hose level. Refer to
COOLING SYSTEM.
(7) Remove heater hoses at engine.
(8) Remove fasteners attaching exhaust manifold
heat shield.
(9) Remove heat shield.
(10) Remove upper exhaust manifold attaching fas-
teners.
(11) Raise vehicle on hoist.
(12) Disconnect exhaust pipe from manifold.
(13) Remove fasteners attaching starter. Move
starter aside.
(14) Remove lower exhaust manifold attaching fas-
teners.
(15) Remove exhaust manifold and gasket (Fig.
52). Manifold is removed from below the engine com-
partment.
Fig. 50 Heater Hoses and Tubes Removal /
Installation
1 ± HEATER HOSES AND TUBES
2 ± ROUTING/RETAINING CLIPS
Fig. 51 Intake Manifold Tightening Sequence
9 - 36 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (9) Install A/C compressor and fasteners.
(10) Install accessory drive belt.
(11) Install air cleaner assembly, resonator assem-
bly and air inlet hose.
(12) Install battery and connect cables.
(13) Fill cooling system.
LEFT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable for battery.
(2) Hoist vehicle.
(3) Disconnect exhaust pipe at manifold.
(4) Lower vehicle.
(5) Remove the front two exhaust heat shield
retaining fasteners. Raise vehicle and remove the
fasteners at rear of heat shield.
(6) Remove heat shield (Fig. 53).
(7) Lower vehicle and remove the upper exhaust
manifold retaining bolts (Fig. 53).
(8) Raise vehicle and remove the lower exhaust
manifold retaining bolts (Fig. 53).
(9) Remove exhaust manifold and gasket (Fig. 53).
Manifold is removed from below the engine compart-
ment.
INSTALLATION
(1) Install exhaust manifold and gasket from below
engine compartment.
(2) Install lower exhaust manifold fasteners (Fig.
53). DO NOT tighten until all fasteners are in place.
(3) Lower vehicle and install upper exhaust mani-
fold fasteners (Fig. 53). Tighten all manifold bolts
starting at center and working outward to 25 N´m
(18 ft. lbs.).
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(4) Install exhaust manifold heat shield (Fig. 53).
Tighten fasteners to 8 N´m (72 in. lbs.), then loosen
45 degrees.
(5) Connect exhaust pipe to manifold.
(6) Connect negative cable to battery.
CYLINDER HEAD COVER
REMOVAL
LEFT SIDE COVER
(1) Disconnect negative cable from battery.
(2) Remove the resonator assemble and air inlet
hose.
(3) Disconnect injector connectors and un-clip the
injector harness.
(4) Route injector harness in front of cylinder head
cover.(5) Disconnect the left side breather tube and
remove the breather tube.
(6) Remove the cylinder head cover mounting
bolts.
(7) Remove cylinder head cover and gasket.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the cylin-
der head cover. Prolonged contact with other
objects may wear a hole in the engine cylinder head
cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Install cylinder head cover and hand start all
fasteners. Verify that all studs are in the correct loca-
tion shown in (Fig. 54).
(3) Tighten cylinder head cover bolts and double
ended studs to 12 N´m (105 in. lbs.).
(4) Install left side breather and connect breather
tube.
(5) Connect injector electrical connectors and injec-
tor harness retaining clips.
(6) Install the resonator and air inlet hose.
(7) Connect negative cable to battery.
REMOVAL
RIGHT SIDE COVER
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
(3) Drain cooling system, below the level of the
heater hoses. Refer to COOLING SYSTEM.
(4) Remove accessory drive belt.
(5) Remove air conditioning compressor retaining
bolts and move compressor to the left.
(6) Remove heater hoses.
(7) Disconnect injector and ignition coil connectors.
(8) Disconnect and remove positive crankcase ven-
tilation (PCV) hose.
(9) Remove oil fill tube.
(10) Un-clip injector and ignition coil harness and
move away from cylinder head cover.
(11) Remove right rear breather tube and filter
assembly.
9 - 38 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (4) For rocker arm installation on cylinders 1 and
7 Rotate the crankshaft until cylinder #2 is at TDC
compression stroke.
(5) Using special tool 8516 press downward on the
valve spring, install rocker arm (Fig. 56).
(6) Install the cylinder head cover.
CYLINDER HEADS
CYLINDER HEADÐLEFT
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Disconnect the exhaust pipe at the left side
exhaust manifold.
(4) Drain the engine coolant. Refer to COOLING
SYSTEM.
(5) Lower the vehicle.
(6) Remove the intake manifold. Refer to proce-
dure in this section.
(7) Remove the cylinder head cover. Refer to proce-
dure in this section.
(8) Remove the fan shroud and fan blade assembly.
Refer to COOLING SYSTEM.
(9) Remove accessory drive belt. Refer to COOL-
ING SYSTEM.
(10) Remove the power steering pump and set
aside.(11) Rotate the crankshaft until the damper timing
mark is aligned with TDC indicator mark (Fig. 57).
(12) Verify the V8 mark on the camshaft sprocket
is at the 12 o'clock position (Fig. 59). Rotate the
crankshaft one turn if necessary.
(13) Remove the crankshaft damper. Refer to
Crankshaft Damper in this section.
(14) Remove the timing chain cover. Refer to pro-
cedure in this section.
(15) Lock the secondary timing chains to the idler
sprocket using Special Tool 8515 (Fig. 58).
NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(16) Mark the secondary timing chain, one link on
each side of the V8 mark on the camshaft drive gear
(Fig. 59).
(17) Remove the left side secondary chain ten-
sioner. Refer to Timing Chain and Sprockets in this
section.
(18) Remove the cylinder head access plug (Fig.
60).
(19) Remove the left side secondary chain guide.
Refer to Timing Chain and Sprockets in this section.
(20) Remove the retaining bolt and the camshaft
drive gear.
Fig. 56 Rocker ArmÐRemoval
1 ± CAMSHAFT
2 ± SPECIAL TOOL 8516
Fig. 57 Engine Top Dead Center (TDC) Indicator
Mark
1 ± TIMING CHAIN COVER
2 ± CRANKSHAFT TIMING MARKS
DN4.7L ENGINE 9 - 41
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (14) Install the crankshaft damper. Tighten
damper bolt 175 N´m (130 Ft. Lbs.).
(15) Install the power steering pump.
(16) Install the fan blade assembly and fan
shroud.
(17) Install the cylinder head cover.
(18) Install the intake manifold.
(19) Refill the cooling system
(20) Raise the vehicle.
(21) Install the exhaust pipe onto the left exhaust
manifold.
(22) Lower the vehicle.
(23) Connect the negative cable to the battery.
(24) Start the engine and check for leaks.
CYLINDER HEADÐRIGHT
REMOVAL
(1) Disconnect battery negitive cable.
(2) Raise the vehicle on a hoist.
(3) Disconnect the exhaust pipe at the right side
exhaust manifold.
(4) Drain the engine coolant. Refer to COOLING
SYSTEM.
(5) Lower the vehicle.
(6) Remove the intake manifold. Refer to proce-
dure in this section.
(7) Remove the cylinder head cover. Refer to proce-
dure in this section.
(8) Remove the fan shroud. Refer to COOLING
SYSTEM.
(9) Remove oil fill housing from cylinder head.
(10) Remove accessory drive belt. Refer to COOL-
ING SYSTEM.
(11) Rotate the crankshaft until the damper timing
mark is aligned with TDC indicator mark (Fig. 57).
(12) Verify the V8 mark on the camshaft sprocket
is at the 12 o'clock position (Fig. 59). Rotate the
crankshaft one turn if necessary.
(13) Remove the crankshaft damper. Refer to
Crankshaft Damper in this section.(14) Remove the timing chain cover. Refer to Tim-
ing Chain Cover in this section.
(15) Lock the secondary timing chains to the idler
sprocket using Special Tool 8515 (Fig. 58).
NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(16) Mark the secondary timing chain, one link on
each side of the V8 mark on the camshaft drive gear
(Fig. 59).
(17) Remove the right side secondary chain ten-
sioner. Refer to Timing Chain and Sprockets in this
section.
(18) Remove the cylinder head access plug (Fig.
64).
(19) Remove the right side secondary chain guide.
Refer to Timing Chain and Sprockets in this section.
(20) Remove the retaining bolt and the camshaft
drive gear.
CAUTION: Do not allow the engine to rotate. severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason. A damaged target wheel
can result in a vehicle no start condition.
Fig. 63 Cylinder Head Tightening Sequence
Fig. 64 Cylinder Head Access Plugs
1 ± RIGHT CYLINDER HEAD ACCESS PLUG
2 ± LEFT CYLINDER HEAD ACCESS PLUG
9 - 44 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
(1) Install hydraulic lash adjuster making sure
adjusters are at least partially full of oil. This can be
verified by little or no plunger travel when lash
adjuster is depressed.
(2) Install rocker arm(s). Refer to procedure in this
section.
(3) Install cylinder head cover(s). Refer to proce-
dure in this section.
CRANKSHAFT DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt. Refer to COOL-
ING SYSTEM.
(3) Drain cooling system. Refer to COOLING SYS-
TEM.
(4) Remove radiator upper hose.
(5) Remove upper fan shroud. Refer to COOLING
SYSTEM.
(6) Using Special Tools 6958 Spanner with Adapter
Pins 8346, loosen fan and viscous assembly from
water pump (Fig. 69).
(7) Remove fan and viscous assembly.
(8) Disconnect electrical connector for fan mounted
inside radiator shroud.NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
(9) Remove crankshaft damper bolt.
(10) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 70).
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Align crankshaft damper slot with key in
crankshaft. Slide damper onto crankshaft slightly.
CAUTION: Special Tool 8512, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
(2) Assemble Special Tool 8512 as follows, The nut
is threaded onto the shaft first. Then the roller bear-
ing is placed onto the threaded rod (The hardened
bearing surface of the bearingMUSTface the nut).
Then the hardened washer slides onto the threaded
rod (Fig. 71). Once assembled coat the threaded rod's
threads with MopartNickel Anti-Seize or (Loctite
No. 771).
Fig. 68 Valve Assembly Configuration
1 ± VALVE LOCKS (3±BEAD)
2 ± RETAINER
3 ± VALVE STEM OIL SEAL
4 ± INTAKE VALVE
5 ± EXHAUST VALVE
6 ± VALVE SPRINGFig. 69 Fan AssemblyÐRemoval/Installation
1 ± SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2±FAN
DN4.7L ENGINE 9 - 47
REMOVAL AND INSTALLATION (Continued)