Dodge 2000 Durango Service Manual
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Dodge 2000 Durango Service Manual

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DN
4.7L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.2L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . 3
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . 5
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PISTON AND CONNECTING ROD . . . . . . . . . . . . . 5
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . 5
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VALVE STEM SEAL . . . . . . . . . . . . . . . . . . . . . . . . 5
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HYDRAULIC LASH ADJUSTER . . . . . . . . . . . . . . . 6
TIMING DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . 6
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . 6
OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STRUCTURAL DUST COVER . . . . . . . . . . . . . . . . 7
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 7
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE DIAGNOSIS-MECHANICAL. . . . . . . . . 10
SERVICE DIAGNOSIS-LUBRICATION. . . . . . . . . 11
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 12
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . 13
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHECKING ENGINE OIL PRESSURE. . . . . . . . . . 15
ENGINE

TABLE OF CONTENTS

page
5.9L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.7L ENGINE
TABLE OF CONTENTS
page
FORM-IN-PLACE GASKETS. . . . . . . . . . . . . . . . . 15
ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CYLINDER BORE-HONING . . . . . . . . . . . . . . . . 18
HYDROSTATIC LOCK . . . . . . . . . . . . . . . . . . . . . 18
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE TIMING-VERIFICATION . . . . . . . . . . . . 19
TIMING CHAIN-MEASURING WEAR . . . . . . . . . 22
PISTONS-FITTING . . . . . . . . . . . . . . . . . . . . . . . 22
PISTON RINGS-FITTING . . . . . . . . . . . . . . . . . . 24
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . . 27
ENGINE MOUNTS-LEFT AND RIGHT. . . . . . . . . 28
ENGINE MOUNT-REAR . . . . . . . . . . . . . . . . . . . 29
STRUCTURAL COVER. . . . . . . . . . . . . . . . . . . . . 30
ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 31
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 35
EXHAUST MANIFOLDS . . . . . . . . . . . . . . . . . . . . 36
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . 38
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . 40
CYLINDER HEADS. . . . . . . . . . . . . . . . . . . . . . . . 41
VALVE SPRINGS AND SEALS . . . . . . . . . . . . . . . 46
HYDRAULIC LASH ADJUSTER . . . . . . . . . . . . . . 46
CRANKSHAFT DAMPER . . . . . . . . . . . . . . . . . . . 47
TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . . 48
TIMING CHAIN AND SPROCKETS . . . . . . . . . . . . 49
IDLER SHAFT-TIMING DRIVE . . . . . . . . . . . . . . 55
CAMSHAFTS-IN VEHICLE . . . . . . . . . . . . . . . . . 56
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . . 61
OIL PAN 4X2 VEHICLE. . . . . . . . . . . . . . . . . . . . . 61
OIL PAN 4X4 VEHICLE. . . . . . . . . . . . . . . . . . . . . 64
PISTON AND CONNECTING ROD . . . . . . . . . . . . 65
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
FLEXPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
ENGINE
9 - 1
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Andrew
April 14, 2025

Trying to.figure out where the plug ins.from power distribution box plug into harness on 2000 durango slt 5.9

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Mr. Anderson
April 15, 2025

The plug-ins from the power distribution box connect to the headlamp and dash wire harness on a 2000 Dodge Durango SLT 5.9.

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Summary of Contents for Dodge 2000 Durango

  • Page 1: Table Of Contents

    ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page 4.7L ENGINE......1 5.9L ENGINE.

  • Page 2: L Engine

    9 - 2 4.7L ENGINE OIL PUMP ......69 CYLINDER HEADS......75 ENGINE OIL PRESSURE SENDING UNIT .

  • Page 3: Engine

    4.7L ENGINE 9 - 3 DESCRIPTION AND OPERATION (Continued) firing order is 1–8–4–3–6–5–7–2. The engine serial number is located at the right front side of the engine block (Fig. 1) ENGINE LUBRICATION SYSTEM DESCRIPTION The lubrication system (Fig. 2) is a full flow filtra- tion pressure feed type.
  • Page 4 9 - 4 4.7L ENGINE DESCRIPTION AND OPERATION (Continued) Fig. 2 Engine Oil Lubrication System 1 – LEFT CYLINDER HEAD OIL GALLERY 7 – TO CRANKSHAFT MAIN JOURNALS 2 – OIL PRESSURE SENSOR LOCATION 8 – RIGHT CYLINDER HEAD OIL GALLERY 3 –...

  • Page 5: Cylinder Block

    4.7L ENGINE 9 - 5 2000 DN Service Manual DESCRIPTION AND OPERATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 ENGINE LUBRICATION FLOW CHART—CYLINDER HEADS: TABLE 2 FROM 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.

  • Page 6: Valve Spring

    9 - 6 4.7L ENGINE DESCRIPTION AND OPERATION (Continued) VALVE SPRING There are two secondary drive chains, both are inverted tooth type, one to drive the camshaft in each SOHC cylinder head. There are no shaft speed DESCRIPTION changes in the secondary chain drive system. Each The valve springs are made from high strength secondary chain drives a thirty tooth cam sprocket chrome silicon steel.

  • Page 7: Oil Pan

    4.7L ENGINE 9 - 7 DESCRIPTION AND OPERATION (Continued) OIL PAN mance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve DESCRIPTION sealing to the cylinder head. The exhaust manifolds The engine oil pan is made of laminated steel and are covered by a three layer laminated heat shield has a single plane sealing surface.

  • Page 8: Service Diagnosis-Performance

    9 - 8 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary. 2. Corroded or loose battery 2. Clean and tighten battery connections. connections. Apply a coat of light mineral grease to the terminals.
  • Page 9 4.7L ENGINE 9 - 9 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Incorrect ignition timing. 1. Refer to Group 8D, Ignition System. 2. Worn or burned distributor rotor. 2. Replace distributor rotor. 3. Worn distributor shaft. 3.

  • Page 10: Service Diagnosis-Mechanical

    9 - 10 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—MECHANICAL CONDITION POSSIBLE CAUSES CORRECTIONS NOISY VALVES 1. High or low oil level in 1. Refer to Group 0, Lubrication and crankcase. Maintenance. 2. Thin or diluted oil. 2. Change oil and filter. 3.

  • Page 11: Service Diagnosis-Lubrication

    4.7L ENGINE 9 - 11 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—LUBRICATION CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or (b) Tighten fasteners, Repair or porous metal parts. replace metal parts.

  • Page 12: Cylinder Head Gasket Failure Diagnosis

    9 - 12 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) Otherwise the indicated compression pressures may COOLING SYSTEM TESTER METHOD not be valid for diagnosis purposes. (1) Clean the spark plug recesses with compressed WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCES- air.

  • Page 13: Engine Oil Leak Inspection

    4.7L ENGINE 9 - 13 DIAGNOSIS AND TESTING (Continued) CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION AIR ESCAPES THROUGH Intake valve bent, burnt, or not Inspect valve and valve seat. THROTTLE BODY seated properly Reface or replace, as necessary AIR ESCAPES THROUGH Exhaust valve bent, burnt, or not Inspect valve and valve seat.

  • Page 14: Rear Seal Area Leaks-Inspection

    9 - 14 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) filter runoff, and main bearing cap to cylinder crankshaft seal surface is damaged. The seal area on block mating surfaces. the crankshaft could have minor nicks or scratches (4) If no leaks are detected, pressurize the crank- that can be polished out with emery cloth.

  • Page 15: Checking Engine Oil Pressure

    4.7L ENGINE 9 - 15 DIAGNOSIS AND TESTING (Continued) CHECKING ENGINE OIL PRESSURE have different properties and cannot be used inter- changeably. (1) Remove oil pressure sending unit (Fig. 3) and install gauge assembly C-3292. MOPAR SILICONE RUBBER ADHESIVE SEALANT Mopar Silicone Rubber Adhesive Sealant, normally black in color, is available in 3 ounce tubes.

  • Page 16: Engine Oil

    9 - 16 4.7L ENGINE SERVICE PROCEDURES (Continued) locating dowel is recommended during assembly to ENERGY CONSERVING OIL prevent smearing the material off location. An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CON- ENGINE OIL SERVING is located on the label of an engine oil con- tainer.

  • Page 17: Repair Damaged Or Worn Threads

    4.7L ENGINE 9 - 17 SERVICE PROCEDURES (Continued) CRANKCASE OIL LEVEL INSPECTION OIL FILTER REMOVAL (1) Position a drain pan under the oil filter. CAUTION: Do not overfill crankcase with engine oil, (2) Using a suitable oil filter wrench loosen filter. pressure loss or oil foaming can result.

  • Page 18: Cylinder Bore-Honing

    9 - 18 4.7L ENGINE SERVICE PROCEDURES (Continued) The hone marks should INTERSECT at 50° to 60° for proper seating of rings (Fig. 9). Fig. 8 Oil Filter Sealing Surface—Typical 1 – SEALING SURFACE 2 – RUBBER GASKET 3 – OIL FILTER Damaged or worn threads can be repaired.

  • Page 19: Valve Service

    4.7L ENGINE 9 - 19 SERVICE PROCEDURES (Continued) (6) Identify the fluid in the cylinders (i.e. coolant, fuel, oil, etc.). (7) Make sure all fluid has been removed from the cylinders. (8) Repair engine or components as necessary to prevent this problem from occurring again. (9) Squirt engine oil into the cylinders to lubricate the walls.
  • Page 20 9 - 20 4.7L ENGINE SERVICE PROCEDURES (Continued) SINGLE CAMSHAFT TIMING NOTE: to adjust the timing on one camshaft, pre- form the following procedure. (1) Using Chain Tensioner Wedge, special tool 8350, stabilize the secondary chain drive. For refer- ence purposes, mark the chain-to-sprocket position (Fig.
  • Page 21 4.7L ENGINE 9 - 21 SERVICE PROCEDURES (Continued) Fig. 12 Camshaft Sprocket V8 Marks 1 – LEFT CYLINDER HEAD 2 – RIGHT CYLINDER HEAD Fig. 13 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 – LEFT CYLINDER HEAD 3 – SPECIAL TOOL 8350 WEDGE 2 –...

  • Page 22: Timing Chain-Measuring Wear

    9 - 22 4.7L ENGINE SERVICE PROCEDURES (Continued) Fig. 14 Camshaft Dowel To Sprocket Alignment 1 – ADJUSTABLE PLIERS 2 – CAMSHAFT DOWEL TIMING CHAIN—MEASURING WEAR Fig. 15 Camshaft Sprocket Installation—Left NOTE: This procedure must be performed with the Cylinder Head timing chain cover removed.
  • Page 23 4.7L ENGINE 9 - 23 SERVICE PROCEDURES (Continued) Fig. 18 Moly Coated Piston 1 – MOLY COATED Fig. 16 Camshaft Sprocket Installation—Right 2 – MOLY COATED Cylinder Head 1 – TORQUE WRENCH 2 – SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 3 –...

  • Page 24: Piston Rings-Fitting

    9 - 24 4.7L ENGINE 2000 DN Service Manual SERVICE PROCEDURES (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 PISTON RINGS—FITTING RING END GAP Before reinstalling used rings or installing new rings, the ring clearances must be checked. (1) Wipe the cylinder bore clean. (2) Insert the ring in the cylinder bore.

  • Page 25: Connecting Rod Bearings-Fitting

    4.7L ENGINE 9 - 25 SERVICE PROCEDURES (Continued) NOTE: Piston rings are installed in the following order: • Oil ring expander. • Upper oil ring side rail. • Lower oil ring side rail. • No. 2 Intermediate piston ring. • No. 1 Upper piston ring. (8) Install the oil ring expander.
  • Page 26 9 - 26 4.7L ENGINE SERVICE PROCEDURES (Continued) Fig. 25 Connecting Rod Bearing Inspection 1 – UPPER BEARING HALF 2 – MATING EDGES 3 – GROOVES CAUSED BY ROD BOLTS SCRATCHING JOURNAL DURING INSTALLATION 4 – WEAR PATTERN — ALWAYS GREATER ON UPPER BEARING 5 –...

  • Page 27: Crankshaft Main Bearings

    4.7L ENGINE 9 - 27 SERVICE PROCEDURES (Continued) Fig. 30 Checking Connecting Rod Side Clearance— Fig. 29 Measuring Bearing Clearance with Typical Plastigage 1 – PLASTIGAGE SCALE 2 – COMPRESSED PLASTIGAGE Bearing SIZE USED WITH Mark JOURNAL SIZE .025 US .025 mm 50.983-50.967 mm (.001 in.)

  • Page 28: Removal And Installation

    9 - 28 4.7L ENGINE SERVICE PROCEDURES (Continued) nal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance. Install the crankshaft into the cylinder block. Refer to Crankshaft in this section for procedure. CRANKSHAFT MAIN BEARING SELECTION (1) Service main bearings are available in three grades.

  • Page 29: Engine Mount-Rear

    4.7L ENGINE 9 - 29 REMOVAL AND INSTALLATION (Continued) (4) Remove the four bolts and washers retaining the mount to the transmission (4x4 automatic trans- mission only) (Fig. 38). (5) Raise the transmission enough to remove the through bolt (Manual transmission and 4x2 auto- matic transmission only) (Fig.

  • Page 30: Structural Cover

    9 - 30 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) STRUCTURAL COVER REMOVAL (1) Raise vehicle on hoist. (2) Remove the left hand exhaust pipe from exhaust manifold. Refer to Group 11, Exhaust Sys- tem. (3) Loosen the right hand exhaust manifold-to-ex- haust pipe retaining bolts.

  • Page 31: Engine Assembly

    4.7L ENGINE 9 - 31 REMOVAL AND INSTALLATION (Continued) SEQUENCE ITEM TORQUE BOLT 54 N·m (Qty 4) (40 ft. lbs.) BOLT 54 N·m (Qty 2) (40 ft. lbs.) BOLT 54 N·m (Qty 2) (40 ft. lbs.) ENGINE ASSEMBLY REMOVAL NOTE: This procedure applies to both the 4X2 and 4X4 vehicles, steps that apply to the 4X4 vehicle only, are identified.
  • Page 32 9 - 32 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 41 Engine Mount Through Bolt and Nut Removal / Installation—4X4 Vehicles 1 – ENGINE MOUNT BRACKET (2) Fig. 42 Axle Isolator Bracket Removal / 2 – THROUGH BOLT (2) 3 – LOCKNUT AND WASHER (2) Installation—4X4 Vehicles With Automatic 4 –...
  • Page 33 4.7L ENGINE 9 - 33 REMOVAL AND INSTALLATION (Continued) Fig. 45 Heater Hoses and Tubes Removal / Installation Fig. 43 Crankshaft Position Sensor 1 – HEATER HOSES AND TUBES 1 – CRANKSHAFT POSITION SENSOR 2 – ROUTING/RETAINING CLIPS 2 – CYLINDER HEAD COVER 3 –...
  • Page 34 9 - 34 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 46 Throttle Body Connection Points 1 – THROTTLE BODY 2 – TPS 3 – IAC MOTOR Fig. 47 Engine Lifting Fixture Attachment Locations 4 – IAT SENSOR 1 – ATTACHING LOCATION 5 –...

  • Page 35: Intake Manifold

    4.7L ENGINE 9 - 35 REMOVAL AND INSTALLATION (Continued) 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.

  • Page 36: Exhaust Manifolds

    9 - 36 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (12) Connect electrical connectors for the following components: • Manifold Absolute Pressure (MAP) Sensor • Intake Air Temperature (IAT) Sensor • Throttle Position (TPS) Sensor • Coolant Temperature (CTS) Sensor • Idle Air Control (IAC) Motor •...
  • Page 37 4.7L ENGINE 9 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 52 Exhaust Manifold—Right ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE Stud (Qty 2) Nut (Qty 2) 8 N·m (72 in. lbs.), then 25 N·m loosen 45 Bolt (Qty 4) Nut (Qty 2) (18 ft.

  • Page 38: Cylinder Head Cover

    9 - 38 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (9) Install A/C compressor and fasteners. (5) Disconnect the left side breather tube and (10) Install accessory drive belt. remove the breather tube. (11) Install air cleaner assembly, resonator assem- (6) Remove the cylinder head cover mounting bly and air inlet hose.
  • Page 39 4.7L ENGINE 9 - 39 REMOVAL AND INSTALLATION (Continued) Fig. 53 Exhaust Manifold—Left ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE Stud (Qty 2) Nut (Qty 2) 8 N·m (72 in. lbs.), then loosen 25 N·m (18 ft. Bolt (Qty 4) Nut (Qty 2) 45 degrees lbs.) Stud (Qty 2)

  • Page 40: Rocker Arms

    9 - 40 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (5) Connect injector, ignition coil electrical connec- tors and harness retaining clips. (6) Install the oil fill tube. (7) Install PCV hose. (8) Install heater hoses. (9) Install air conditioning compressor retaining bolts.

  • Page 41: Cylinder Heads

    4.7L ENGINE 9 - 41 REMOVAL AND INSTALLATION (Continued) (11) Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (Fig. 57). Fig. 56 Rocker Arm—Removal 1 – CAMSHAFT 2 – SPECIAL TOOL 8516 Fig. 57 Engine Top Dead Center (TDC) Indicator Mark (4) For rocker arm installation on cylinders 1 and 1 –...

  • Page 42: Right Cylinder Head

    9 - 42 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) 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. NOTE: The cylinder head is attached to the cylinder block with fourteen bolts.
  • Page 43 4.7L ENGINE 9 - 43 REMOVAL AND INSTALLATION (Continued) (21) Remove the cylinder head retaining bolts. (22) Remove the cylinder head and gasket. Discard the gasket. CAUTION: Do not lay the cylinder head on its gas- ket sealing surface, due to the design of the cylin- der head gasket any distortion to the cylinder head sealing surface may prevent the gasket from prop- erly sealing resulting in leaks.
  • Page 44 9 - 44 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (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.
  • Page 45 4.7L ENGINE 9 - 45 REMOVAL AND INSTALLATION (Continued) NOTE: The cylinder head is attached to the cylinder (2) Position the new cylinder head gasket on the block with fourteen bolts. locating dowels. (21) Remove the cylinder head retaining bolts. CAUTION: When installing cylinder head, use care (22) Remove the cylinder head and gasket.

  • Page 46: Valve Springs And Seals

    9 - 46 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (14) Install crankshaft damper. Tighten NOTE: All eight valve springs and seals are damper bolt 175 N·m (130 Ft. Lbs.). removed in the same manner; this procedure only (15) Install accessory drive belt. covers one valve seal and valve spring.

  • Page 47: Crankshaft Damper

    4.7L ENGINE 9 - 47 REMOVAL AND INSTALLATION (Continued) Fig. 68 Valve Assembly Configuration Fig. 69 Fan Assembly—Removal/Installation 1 – VALVE LOCKS (3–BEAD) 1 – SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER 2 – RETAINER PINS 8346 3 – VALVE STEM OIL SEAL 2 –...

  • Page 48: Timing Chain Cover

    9 - 48 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 72 Crankshaft Damper—Installation Fig. 70 Crankshaft Damper—Removal 1 – SPECIAL TOOL 8512 1 – SPECIAL TOOL 8513 INSERT 2 – SPECIAL TOOL 1026 (6) Install radiator upper shroud and tighten fas- teners to 11 N·m (95 in.

  • Page 49: Timing Chain And Sprockets

    4.7L ENGINE 9 - 49 REMOVAL AND INSTALLATION (Continued) (9) Fill cooling system. Refer to Group 7, Cooling System for procedures. (10) Connect the battery negative cable. TIMING CHAIN AND SPROCKETS REMOVAL (1) Disconnect negative cable from battery. (2) Drain cooling system. Refer to Group 7, Cooling System for procedures.

  • Page 50: Right Cylinder Head

    9 - 50 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 76 Camshaft Sprocket V8 Marks 1 – LEFT CYLINDER HEAD 2 – RIGHT CYLINDER HEAD Fig. 77 Cylinder Head Access Plug Location 1 – RIGHT CYLINDER HEAD ACCESS PLUG 2 – LEFT CYLINDER HEAD ACCESS PLUG Fig.
  • Page 51 4.7L ENGINE 9 - 51 REMOVAL AND INSTALLATION (Continued) Fig. 79 Camshaft Position Sensor—Removal Fig. 80 Camshaft Rotation—Left Side 1 – CRANKSHAFT POSITION SENSOR 1 – CAMSHAFT SPROCKET AND CHAIN 2 – CYLINDER HEAD COVER 2 – ADJUSTABLE PLIERS 3 – CAMSHAFT POSITION SENSOR 3 –...
  • Page 52 9 - 52 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 82 Timing Chain System 1 – RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN 7 – PRIMARY CHAIN 2 – SECONDARY TIMING CHAIN TENSIONER 8 – IDLER SPROCKET 3 – SECONDARY TENSIONER ARM 9 –...
  • Page 53 4.7L ENGINE 9 - 53 REMOVAL AND INSTALLATION (Continued) the secondary timing chains are installed, position special tool 8515 to hold chains in place for installa- tion (Fig. 84). (8) Align primary chain double plated links with the timing mark at 12 o’clock on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 o’clock on the crankshaft sprocket (Fig.
  • Page 54 9 - 54 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 85 Installing Idler Gear, Primary and Secondary Timing Chains 1 – SPECIAL TOOL 8515 2 – PRIMARY CHAIN IDLER SPROCKET 3 – CRANKSHAFT SPROCKET (13) Remove Special Tool 8515, then attach both sprockets to camshafts.

  • Page 55: Idler Shaft-Timing Drive

    4.7L ENGINE 9 - 55 REMOVAL AND INSTALLATION (Continued) (25) Install the oil fill housing. (26) Install access plug in left cylinder head (Fig. 77). (27) Install power steering pump. Refer to Group 19, Steering for procedure. (28) Install radiator fan shroud. Refer to Group 7, Cooling System for procedure.

  • Page 56: Camshafts-In Vehicle

    9 - 56 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) CAUTION: When removing the cam sprocket, tim- ing chains or camshaft, Failure to use Special Tool 8350 will result in hydraulic tensioner ratchet over extension, requiring timing chain cover removal to reset the tensioner ratchet.

  • Page 57: Special Tool 8350 Wedge

    4.7L ENGINE 9 - 57 REMOVAL AND INSTALLATION (Continued) Fig. 91 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 – LEFT CYLINDER HEAD 3 – SPECIAL TOOL 8350 WEDGE 2 – RIGHT CYLINDER HEAD 4 – SPECIAL TOOL 8350 WEDGE INSTALLATION (1) Lubricate camshaft journals with clean engine oil.
  • Page 58 9 - 58 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (8) Remove excess oil from bolt, then install the camshaft sprocket retaining bolt and hand tighten. (9) Remove Special Tool 8350 timing chain wedge (Fig. 91). (10) Using Special Tool 6958 spanner wrench with adapter pins 8346 (Fig.
  • Page 59 4.7L ENGINE 9 - 59 REMOVAL AND INSTALLATION (Continued) Fig. 95 Camshaft Sprocket Installation 1 – ADJUSTABLE PLIERS 2 – CAMSHAFT DOWEL (2) Set engine to TDC cylinder #1, camshaft sprocket V8 marks at the 12 o’clock position. Fig. 96 Tightening Left Side Cam Sprocket (3) Mark one link on the secondary timing chain Retaining Bolt on both sides of the V8 mark on the camshaft...
  • Page 60 9 - 60 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 97 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 – LEFT CYLINDER HEAD 3 – SPECIAL TOOL 8350 WEDGE 2 – RIGHT CYLINDER HEAD 4 – SPECIAL TOOL 8350 WEDGE Fig.

  • Page 61: Crankshaft Main Bearings

    4.7L ENGINE 9 - 61 REMOVAL AND INSTALLATION (Continued) INSTALLATION (8) Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and (1) Lubricate camshaft journals with clean engine hand tighten. oil. (9) Remove timing chain wedge special tool 8350 NOTE: Position the right side camshaft so that the (Fig.
  • Page 62 9 - 62 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 101 Timing Chain to Sprocket Alignment 1 – LEFT CYLINDER HEAD 2 – RIGHT CYLINDER HEAD Fig. 103 Tightening Right Side Cam Sprocket Retaining Bolt 1 – TORQUE WRENCH Fig. 102 Camshaft Sprocket Installation 2 –...
  • Page 63 4.7L ENGINE 9 - 63 REMOVAL AND INSTALLATION (Continued) Fig. 105 Checking Crankshaft End Play—Typical CRANKSHAFT END PLAY SPECIFICATION CHART Fig. 104 Main Bearing Markings on Target Wheel New Part: 0.052 - 0.282mm 1 – REARMOST CRANKSHAFT COUNTER WEIGHT Specification (0.002 - 0.011 in.) 2 –...

  • Page 64: Oil Pan 4X4 Vehicle

    9 - 64 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (15) Start engine and check for leaks. OIL PAN 4X4 VEHICLE REMOVAL NOTE: 4X4 vehicles equipped with a 4.7L engine must have the front axle removed before the oil pan can be removed. (1) Remove the front axle from vehicle.

  • Page 65: Piston And Connecting Rod

    4.7L ENGINE 9 - 65 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Clean the oil pan gasket mating surface of the bedplate and oil pan. (2) Position the oil pan gasket and pickup tube with new o-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 28 N·m (20 ft.
  • Page 66 9 - 66 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 114 Piston Ring End Gap Position Fig. 112 Side Rail—Installation 1 – SIDE RAIL UPPER 1 – SIDE RAIL END 2 – NO. 1 RING GAP 3 – PISTON PIN 4 –...

  • Page 67: Crankshaft

    4.7L ENGINE 9 - 67 REMOVAL AND INSTALLATION (Continued) CRANKSHAFT REMOVAL NOTE: To remove the crankshaft from the engine, the engine must be removed from the vehicle. (1) Remove the engine. Refer to Engine Assembly in this section for procedure. (2) Remove the engine oil pump.
  • Page 68 9 - 68 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (1) Lubricate upper main bearing halves with clean engine oil. CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft. NOTE: Apply sealant to the tone wheel retaining screws prior to installation.

  • Page 69: Flexplate

    4.7L ENGINE 9 - 69 REMOVAL AND INSTALLATION (Continued) • Tighten bolts A1– A6 to 27 N·m (20 ft. lbs.) (8) Measure crankshaft end play. Refer to Crank- shaft Main Bearings in this section for procedure. (9) Install the connecting rods and measure side clearance.

  • Page 70: Engine Oil Pressure Sending Unit

    9 - 70 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 121 Bedplate Tightening Sequence Fig. 122 Oil Pan Tightening Sequence ENGINE OIL PRESSURE SENDING UNIT REMOVAL (1) Disconnect the negative cable from the battery. (2) Raise vehicle on hoist. (3) Remove front splash shield. (4) Disconnect oil pressure sender wire (Fig.
  • Page 71 4.7L ENGINE 9 - 71 REMOVAL AND INSTALLATION (Continued) (4) Drain cooling system. Refer to Group 7, Cooling System for procedure. (5) Remove upper radiator hose. (6) Using Special Tools 6958 Spanner with Adapter Pins 8346 loosen fan and viscous assembly from water pump (Fig.
  • Page 72 9 - 72 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 127 Crankshaft Damper—Removal Fig. 129 Crankshaft Front Seal—Installation 1 – SPECIAL TOOL 8513 INSERT 1 – TIMING CHAIN COVER 2 – SPECIAL TOOL 1026 2 – SPECIAL TOOL 8348 3 – SPECIAL TOOL 8512 (2) Assemble Special Tool 8512 as follows, The nut is threaded onto the shaft first.

  • Page 73: Crankshaft Oil Seal-Rear

    4.7L ENGINE 9 - 73 REMOVAL AND INSTALLATION (Continued) (1) If being preformed in vehicle, remove the transmission. Refer to Group 21, Transmission and Transfer Case. (2) Remove the flexplate. Refer to procedure in this section. NOTE: The crankshaft oil seal CAN NOT be reused after removal.

  • Page 74: Engine Core Plugs

    9 - 74 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 135 Engine Core Plug Removal 1 – CYLINDER BLOCK 2 – REMOVE PLUG WITH PLIERS Fig. 133 Crankshaft Rear Oil Seal Guide Special 3 – STRIKE HERE WITH HAMMER Tool 8349–2 and Oil Seal 4 –...

  • Page 75: Cleaning And Inspection Intake Manifold

    4.7L ENGINE 9 - 75 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: Once the oil pressure relief valve, cup plug, (3) Inspect the manifold to exhaust pipe mating and pin are removed, the pump assembly must be surface for cracks, gouges, or other damage that would prevent sealing.

  • Page 76: Piston And Connecting Rod

    9 - 76 4.7L ENGINE CLEANING AND INSPECTION (Continued) PISTON AND CONNECTING ROD (1) Clean all parts thoroughly. Mating surface of the oil pump housing should be smooth. If the pump cover is scratched or grooved the oil pump assembly CLEANING should be replaced.
  • Page 77 4.7L ENGINE 9 - 77 CLEANING AND INSPECTION (Continued) Fig. 137 Checking Oil Pump Cover Flatness 1 – STRAIGHT EDGE 2 – FEELER GAUGE 3 – OIL PUMP COVER Fig. 140 Measuring Outer Rotor Clearance in Housing 1 – FEELER GAUGE 2 –...

  • Page 78: Specifications

    9 - 78 4.7L ENGINE CLEANING AND INSPECTION (Continued) (4) Determine taper by subtracting the smaller diameter from the larger diameter. (5) Rotate measuring device 90° and repeat steps above. (6) Determine out-of-roundness by comparing the difference between each measurement. (7) If cylinder bore taper does not exceed 0.025 mm (0.001 inch) and out-of-roundness does not exceed 0.025 mm (0.001 inch), the cylinder bore can...
  • Page 79 4.7L ENGINE 9 - 79 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION No. 3 83.88 - 84.08 mm Bearing Bore Out of 0.004 mm Round (3.302 - 3.310 in.) (MAX) (0.0002 in.) PISTON PINS Total Weight (Less 578 grams (20.388 Type Pressed Fit Bearing) ounces)
  • Page 80 9 - 80 4.7L ENGINE 2000 DN Service Manual SPECIFICATIONS (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Spring Force (Valve Exhaust Closed) Opens (BTDC) 232.5° Intake and Exhaust 315.5 - 352.5 N @ 40.89 Closes (ATDC) 21.2°...
  • Page 81 4.7L ENGINE 9 - 81 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION N·m OIL PUMP Lbs. Lbs. Clearance Over Rotors .035 -.095 mm Flexplate—Bolts — (MAX) Engine Mount Bracket to — (0.0014 - 0.0038 in.) Block—Bolts Cover Out - of -Flat .025 mm (0.001 in.) Rear Mount to —...

  • Page 82: Special Tools

    9 - 82 4.7L ENGINE SPECIAL TOOLS 4.7L ENGINE Front Crankshaft Seal Remover 8511 Spanner Wrench 6958 Front Crankshaft Seal Installer 8348 Adapter Pins 8346 Engine Lifting Studs 8400 Handle C-4171 Engine Lift Fixture 8347 Rear Crankshaft Seal Installer 8349...
  • Page 83 4.7L ENGINE 9 - 83 SPECIAL TOOLS (Continued) Crankshaft Damper Removal Insert 8513 Rear Crankshaft Seal Remover 8506 Connecting Rod Guides 8507 Chain Tensioner Wedge 8350 Crankshaft Damper Installer 8512 Chain Tensioner Pins 8514 Puller 1026 Secondary Chain Holder 8515...
  • Page 84 9 - 84 4.7L ENGINE SPECIAL TOOLS (Continued) Valve Spring Tester C-647 Remover, Rocker Arm 8516 Dial Indicator C-3339 Valve Spring Compressor 8387 Valve Spring Compressor C-3422-B Idler Shaft Remover 8517 Bore Size Indicator C-119 Valve Spring Compressor Adapters 8519 Oil Pressure Gauge C-3292...
  • Page 85 4.7L ENGINE 9 - 85 SPECIAL TOOLS (Continued) Pressure Tester Kit 7700 Piston Ring Compressor C-385 Bloc–Chek–Kit C-3685–A...
  • Page 86 9 - 86 5.2L ENGINE 5.2L ENGINE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CYLINDER HEAD ......107 ENGINE .

  • Page 87: Description And Operation

    5.2L ENGINE 9 - 87 DESCRIPTION AND OPERATION (Continued) Fig. 3 Positive Displacement Oil Pump—Typical 1 – INNER ROTOR AND SHAFT 2 – BODY 3 – DISTRIBUTOR DRIVESHAFT (REFERENCE) Fig. 1 Firing Order 4 – COTTER PIN 5 – RETAINER CAP 6 –...
  • Page 88 9 - 88 5.2L ENGINE DESCRIPTION AND OPERATION (Continued)

  • Page 89: Exhaust Manifold

    5.2L ENGINE 9 - 89 DESCRIPTION AND OPERATION (Continued) 1 – OIL DEFLECTOR TAB 14 – OIL PUMP 2 – BOLT 15 – OIL FILTER 3 – ROCKER ARM PIVOT 16 – CRANKSHAFT 4 – ROCKER ARM 17 – FROM OIL PUMP 5 –...

  • Page 90: Cylinder Head Cover Gasket

    9 - 90 5.2L ENGINE DESCRIPTION AND OPERATION (Continued) CYLINDER HEAD COVER GASKET OPERATION The cylinder head closes the combustion chamber DESCRIPTION allowing the pistons to compress the air fuel mixture to the correct ratio for ignition. The valves located in The cylinder head cover gasket is a steel-backed the cylinder head open and close to either allow clean silicone gasket, designed for long life usage (Fig.

  • Page 91: Crankshaft Main Bearings

    5.2L ENGINE 9 - 91 DESCRIPTION AND OPERATION (Continued) CRANKSHAFT MAIN BEARINGS DESCRIPTION Main bearings are located in the cylinder block. One half of the main bearing is located in the crank- shaft main bore the other half of the matching bear- ing is located in the main bearing cap (Fig.

  • Page 92: Engine Performance

    9 - 92 5.2L ENGINE SERVICE PROCEDURES (Continued) Scrape or wire brush all gasket surfaces to remove (9) Inspect crankcase ventilation system as out all loose material. Inspect stamped parts to ensure lined in Group 0, Lubrication and Maintenance. For gasket rails are flat.
  • Page 93 5.2L ENGINE 9 - 93 SERVICE PROCEDURES (Continued) particular ambient temperature range and variation To ensure proper lubrication of an engine, the (Fig. 12). engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick.

  • Page 94: Repair Damaged Or Worn Threads

    9 - 94 5.2L ENGINE SERVICE PROCEDURES (Continued) • Tapping the hole with a special Heli-Coil Tap, or equivalent. • Installing an insert into the tapped hole to bring the hole back to its original thread size. CYLINDER BORE—HONING Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.

  • Page 95: Hydrostatic Lock

    5.2L ENGINE 9 - 95 SERVICE PROCEDURES (Continued) (4) A controlled hone motor speed between 200 and (2) Insert a 6.350 mm (1/4 inch) spacer between 300 RPM is necessary to obtain the proper cross- rocker arm pad and stem tip of No.1 intake valve. hatch angle.
  • Page 96 9 - 96 5.2L ENGINE SERVICE PROCEDURES (Continued) (2) Attach Dial Indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 18). Fig. 18 Measuring Valve Guide Wear Fig. 19 Valve Face and Seat Angles 1 –...

  • Page 97: Measuring Timing Chain Stretch

    5.2L ENGINE 9 - 97 SERVICE PROCEDURES (Continued) (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.

  • Page 98: Pistons-Fitting

    9 - 98 5.2L ENGINE SERVICE PROCEDURES (Continued) 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.
  • Page 99 5.2L ENGINE 9 - 99 SERVICE PROCEDURES (Continued) PISTON MEASUREMENT CHART up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point, a stamped letter “O”, an oval depression or the PISTON A DIA = PISTON BORE word TOP (Fig.

  • Page 100: Connecting Rod Bearings-Fitting

    9 - 100 5.2L ENGINE SERVICE PROCEDURES (Continued) 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-...
  • Page 101 5.2L ENGINE 9 - 101 REMOVAL AND INSTALLATION (Continued) (1) Disconnect the negative cable from the battery. (2) Raise vehicle on hoist. (3) Install engine lifting (support) fixture. (4) Remove front axle assembly. (Refer to Group 3, Differential and Driveline in this publication.) (5) Left mount insulator only.

  • Page 102: Engine Mount-Rear

    9 - 102 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 33 Engine Mount Insulator at Frame 1 – NUT 2 – ENGINE SUPPORT BRACKET Fig. 34 Rear Mount Insulator 3 – INSULATOR 4 – NUT 1 – AUTOMATIC TRANSMISSION 5 – THROUGH BOLT 2 –...

  • Page 103: Intake Manifold

    5.2L ENGINE 9 - 103 REMOVAL AND INSTALLATION (Continued) (9) Disconnect the accelerator linkage. (11) Install the generator (refer to Group 8B, Bat- (10) Remove throttle body. tery/Starter/Generator Service). (11) Perform the Fuel System Pressure release (12) Install starter motor (refer to Group 8B, Bat- procedure (refer to Group 14, fuel System).
  • Page 104 9 - 104 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (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.

  • Page 105: Exhaust Manifold

    5.2L ENGINE 9 - 105 REMOVAL AND INSTALLATION (Continued) • Step 1—Tighten bolts 1 thru 4, in sequence, to 8 N·m (72 in. lbs.) torque. Tighten in alternating steps 1.4 N·m (12 in. lbs.) torque at a time. • Step 2—Tighten bolts 5 thru 12, in sequence, to 8 N·m (72 in.

  • Page 106: Cylinder Head Cover

    9 - 106 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 42 Exhaust Manifold Installation—5.9L Engine Fig. 40 Exhaust Manifold Heat Shield—Right Side 1 – EXHAUST MANIFOLD (LEFT) 2 – BOLTS & WASHERS 1 – WASHER 3 – NUTS & WASHERS 2 –...

  • Page 107: Rocker Arms And Push Rods

    5.2L ENGINE 9 - 107 REMOVAL AND INSTALLATION (Continued) (2) Position the cylinder head cover onto the gas- (3) Remove coil wire from distributor and secure to ket. Tighten the bolts to 11 N·m (95 in. lbs.) torque. good ground to prevent engine from starting. (3) Install closed crankcase ventilation system and (4) Using suitable socket and flex handle at crank- evaporation control system.

  • Page 108: Valves And Valve Springs

    9 - 108 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (15) Remove intake manifold and throttle body as (10) Connect the heater hoses and bypass hose. an assembly. Discard the flange side gaskets and the (11) Install distributor cap and wires. front and rear cross-over gaskets.

  • Page 109: Hydraulic Tappets

    5.2L ENGINE 9 - 109 REMOVAL AND INSTALLATION (Continued) spring seat in cylinder head to the bottom surface of (3) Remove the cooling system fan. spring retainer. If spacers are installed, measure (4) Remove the serpentine belt (refer to Group 7, from the top of spacer.

  • Page 110: Timing Chain Cover

    9 - 110 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (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.

  • Page 111: Timing Chain

    5.2L ENGINE 9 - 111 REMOVAL AND INSTALLATION (Continued) the 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.
  • Page 112 9 - 112 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) 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.

  • Page 113: Camshaft Bearings

    5.2L ENGINE 9 - 113 REMOVAL AND INSTALLATION (Continued) Fig. 56 Alignment of Timing Marks Fig. 57 Camshaft Bearings Removal/Installation with 1 – TIMING MARKS Tool C-3132-A 1 – SPECIAL TOOL C-3132–A (13) Install distributor and distributor drive shaft. 2 – MAIN BEARING OIL HOLE (14) Install push rods and tappets.

  • Page 114: Distributor Drive Shaft Bushing

    9 - 114 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION Only one main bearing should be selectively fitted while all other main bearing caps are properly tight- ened. All bearing capbolts removed during service pro- cedures are to be cleaned and oiled before installation. When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side.

  • Page 115: Oil Pan

    5.2L ENGINE 9 - 115 2000 DN Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 Fig. 62 Position of Oil Pump Shaft Slot 1 – DISTRIBUTOR DRIVE After the distributor has been installed, its rota- tional position must be set using the SET SYNC mode of the DRB scan tool.
  • Page 116 9 - 115A 5.2L ENGINE 2000 DN Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 (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.

  • Page 117: Piston And Connecting Rod Assembly

    9 - 116 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) PISTON AND CONNECTING ROD ASSEMBLY (4) Install connecting rod bolt protectors on rod bolts, the long protector should be installed on the numbered side of the connecting rod. REMOVAL (5) Rotate crankshaft so that the connecting rod (1) Remove the engine from the vehicle.

  • Page 118: Oil Pump

    5.2L ENGINE 9 - 117 REMOVAL AND INSTALLATION (Continued) INSTALLATION Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess seal- (1) Clean Gasket Maker residue and sealant from ant off the oil pan seal groove. the cylinder block and rear cap mating surface.

  • Page 119: Crankshaft Oil Seals-Rear

    9 - 118 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) interference. If tool does not fit, the cover must be removed and installed properly. (4) 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 bore of cover.
  • Page 120 5.2L ENGINE 9 - 119 REMOVAL AND INSTALLATION (Continued) (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.

  • Page 121: Engine Core Oil And Camshaft Plugs

    9 - 120 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (6) To align the bearing cap, use cap slot, align- ENGINE CORE OIL AND CAMSHAFT PLUGS ment dowel and cap bolts. DO NOT remove excess Engine core plugs have been pressed into the oil material after assembly.

  • Page 122: Disassembly And Assembly Valve Service

    5.2L ENGINE 9 - 121 REMOVAL AND INSTALLATION (Continued) (2) Attach Dial Indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 76). Fig. 74 Core Hole Plug Removal 1 – CYLINDER BLOCK 2 –...
  • Page 123 9 - 122 5.2L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) REFACING VALVES AND VALVE SEATS The intake and exhaust valves have a 43-1/4° to 43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle (Fig. 77). Fig. 78 Intake and Exhaust Valves 1 –...

  • Page 124: Oil Pump

    5.2L ENGINE 9 - 123 DISASSEMBLY AND ASSEMBLY (Continued) (2) Measure the concentricity of valve seat using a OIL PUMP dial indicator. Total runout should not exceed 0.051 mm (0.002 inch) total indicator reading. DISASSEMBLE (3) Inspect the valve seat with Prussian blue to (1) Remove the relief valve as follows: determine where the valve contacts the seat.

  • Page 125: Cylinder Block

    9 - 124 5.2L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) 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.

  • Page 126: Oil Pump

    5.2L ENGINE 9 - 125 CLEANING AND INSPECTION (Continued) Clean oil pan in solvent and wipe dry with a clean cloth. Clean oil screen and pipe thoroughly in clean sol- vent. Inspect condition of screen. INSPECTION Inspect oil drain plug and plug hole for stripped or damaged threads.
  • Page 127 9 - 126 5.2L ENGINE CLEANING AND INSPECTION (Continued) Fig. 85 Measuring Outer Rotor Thickness Fig. 88 Measuring Clearance Between Rotors 1 – OUTER ROTOR 2 – FEELER GAUGE 3 – INNER ROTOR Place a straightedge across the face of the pump, between bolt holes.

  • Page 128: Cylinder Block

    5.2L ENGINE 9 - 127 CLEANING AND INSPECTION (Continued) • The cylinder bores show a taper of more than If oil pressure was low and pump is within specifi- cations, inspect for worn engine bearings or other 0.254 mm (0.010 inch). •...

  • Page 129: Specifications

    9 - 128 5.2L ENGINE SPECIFICATIONS DESCRIPTION SPECIFICATION 5.2L ENGINE SPECIFICATIONS No. 5 39.688 – 39.713 mm ENGINE SPECIFICATIONS (1.5625 – 1.5635 in.) Bearing Journal Diameter DESCRIPTION SPECIFICATION No. 1 50.749 – 50.775 mm GENERAL SPECIFICATIONS (1.998 – 1.999 in.) No.
  • Page 130 5.2L ENGINE 9 - 129 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Main Bearing Journal CYLINDER HEAD Diameter 63.487 – 63.513 mm Valve Seat (2.4995 – 2.5005 in.) Angle 44.25° – 44.75° Out of Round (Max.) 0.127 mm Runout (Max.) 0.0762 mm (0.001 in.) (0.003 in.) Taper (Max.)
  • Page 131 9 - 130 5.2L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION VALVE SPRINGS OIL PUMP Free Length 49.962 mm Clearance over Rotors 0.0381 mm (Max.) (1.967 in.) (0.0015 in.) Spring Tension Inner Rotor Thickness 20.955 mm valve closed 378 N @ 41.66 mm (Min.) (85 lbs.
  • Page 132 5.2L ENGINE 9 - 131 SPECIFICATIONS (Continued) OVERSIZE AND UNDERSIZE ENGINE DESCRIPTION SPECIFICATION PISTON PIN COMPONENT MARKINGS CHART Clearance in Piston 0.00635 – 0.01905 mm U/S-O/S Item Identification Identification (0.00025 – 0.00075 in.) Location Diameter 24.996 – 25.001 mm Rod/ R or M R-1-4 Milled flat on (0.9841 –...

  • Page 133: Torque Specifications

    9 - 132 5.2L ENGINE SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS DESCRIPTION N·m TORQUE CHART 5.2L ENGINE Lbs. Lbs. Rear Insulator to — DESCRIPTION N·m Transmission— Lbs. Lbs. Bolts (4WD) Camshaft Sprocket—Bolt — Rear Insulator Bracket—Bolts — Camshaft Thrust Plate—Bolts — (4WD Automatic) Chain Case Cover—Bolts —...
  • Page 134 5.2L ENGINE 9 - 133 SPECIAL TOOLS (Continued) Engine Support Fixture C-3487–A Dial Indicator C-3339 Valve Spring Compressor MD-998772–A Puller C-3688 Adapter 6633 Front Oil Seal Installer 6635 Adapter 6716A Cam Bearing Remover/Installer C-3132–A Valve Guide Sleeve C-3973 Camshaft Holder C-3509...
  • Page 135 9 - 134 5.2L ENGINE SPECIAL TOOLS (Continued) Crankshaft Main Bearing Remover C-3059 Distributor Bushing Puller C-3052 Distributor Bushing Driver/Burnisher C-3053 Cylinder Bore Gauge C-119 Piston Ring Compressor C-385...

  • Page 136: 5.9L Engine

    5.9L ENGINE 9 - 135 5.9L ENGINE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION ENGINE REAR SUPPORT ....160 ENGINE ....... 136 ENGINE ASSEMBLY.

  • Page 137: The Cylinders Are Numbered From Front To Rear; 1

    9 - 136 5.9L ENGINE ENGINE LUBRICATION SYSTEM DESCRIPTION AND OPERATION ENGINE DESCRIPTION A gear-type positive displacement pump (Fig. 3) is DESCRIPTION mounted at the underside of the rear main bearing cap. The pump uses a pick-up tube and screen The 5.9 Liter (360 CID) eight-cylinder engine is a assembly to gather engine oil from the oil pan.
  • Page 138 5.9L ENGINE 9 - 137 DESCRIPTION AND OPERATION (Continued) The hydraulic valve tappets receive oil directly tappets, which pass oil through hollow push rods to a from the main oil gallery. The camshaft bearings hole in the corresponding rocker arm. Oil from the receive oil from the main bearing galleries.
  • Page 139 9 - 138 5.9L ENGINE DESCRIPTION AND OPERATION (Continued)

  • Page 140: Exhaust Manifold

    5.9L ENGINE 9 - 139 DESCRIPTION AND OPERATION (Continued) 1 – OIL DEFLECTOR TAB 14 – OIL PUMP 2 – BOLT 15 – OIL FILTER 3 – ROCKER ARM PIVOT 16 – CRANKSHAFT 4 – ROCKER ARM 17 – FROM OIL PUMP 5 –...

  • Page 141: Cylinder Head Cover Gasket

    9 - 140 5.9L ENGINE DESCRIPTION AND OPERATION (Continued) CYLINDER HEAD COVER GASKET OPERATION The cylinder head closes the combustion chamber DESCRIPTION allowing the pistons to compress the air fuel mixture to the correct ratio for ignition. The valves located in The cylinder head cover gasket is a steel-backed the cylinder head open and close to either allow clean silicone gasket, designed for long life usage (Fig.

  • Page 142: Crankshaft Main Bearings

    5.9L ENGINE 9 - 141 DESCRIPTION AND OPERATION (Continued) CRANKSHAFT MAIN BEARINGS DESCRIPTION Main bearings are located in the cylinder block. One half of the main bearing is located in the crank- shaft main bore the other half of the matching bear- ing is located in the main bearing cap (Fig.

  • Page 143: Service Diagnosis-Gasoline Engines

    9 - 142 5.9L ENGINE DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—GASOLINE ENGINES PERFORMANCE DIAGNOSIS CHART—GASOLINE ENGINES CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL 1. Weak or dead battery 1. Charge/Replace Battery. Refer to Group 8A, NOT CRANK Battery, for correct procedures. Check charging system.
  • Page 144 5.9L ENGINE 9 - 143 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Worn or incorrectly gapped spark 3. Replace or clean and re-gap spark plugs (Refer to plugs group 8D, Ignition System) 4. Worn or burned distributor rotor 4.
  • Page 145 9 - 144 5.9L ENGINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION CONNECTING 1. Insufficient oil supply 1. Check engine oil level. (Refer to group 0, Lubrication and ROD NOISE Maintenance) 2. Low oil pressure 2. Check engine oil level. If ok, Perform oil pressure test. Refer to this group for engine oil pressure test/specifications 3.

  • Page 146: Intake Manifold Leakage Diagnosis

    5.9L ENGINE 9 - 145 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Misaligned or 1. Replace gasket deteriorated gaskets 2. Loose fastener, 2. Tighten, repair or replace the part broken or porous metal part 3. Front or rear 3.

  • Page 147: Cylinder Head Gasket Failure Diagnosis

    9 - 146 5.9L ENGINE DIAGNOSIS AND TESTING (Continued) Ensure the battery is completely charged and the COOLING SYSTEM TESTER METHOD engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST.

  • Page 148: Inspection (Engine Oil Leaks In General)

    5.9L ENGINE 9 - 147 DIAGNOSIS AND TESTING (Continued) All gauge pressure indications should be equal, (12) Clean the oil off the suspect oil leak area with no more than 25% leakage. using a suitable solvent. Drive the vehicle at various FOR EXAMPLE: At 552 kPa (80 psi) input pres- speeds approximately 24 km (15 miles).

  • Page 149: Hydraulic Tappets

    9 - 148 5.9L ENGINE DIAGNOSIS AND TESTING (Continued) HYDRAULIC TAPPETS plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is Before disassembling any part of the engine to cor- caused by a tappet check valve not seating, or by for- rect tappet noise, check the oil pressure.

  • Page 150: Service Procedures

    5.9L ENGINE 9 - 149 DIAGNOSIS AND TESTING (Continued) MOPAR GASKET MAKER Mopar Gasket Maker, normally red in color, is available in 6 cc tubes. This anaerobic type gasket material cures in the absence of air when squeezed between smooth machined metallic surfaces. It will not cure if left in the uncovered tube.

  • Page 151: Engine Oil

    9 - 150 5.9L ENGINE SERVICE PROCEDURES (Continued) (2) Check intake manifold bolt torque. (3) Perform cylinder compression test. Refer to Cylinder Compression Pressure Test in the Engine Diagnosis area of this section. (4) Clean or replace spark plugs as necessary and adjust gap as specified in Electrical Group 8D.

  • Page 152: Repair Damaged Or Worn Threads

    5.9L ENGINE 9 - 151 SERVICE PROCEDURES (Continued) (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-...

  • Page 153: Cylinder Bore-Honing

    9 - 152 5.9L ENGINE SERVICE PROCEDURES (Continued) The hone marks should INTERSECT at 50° to 60° for proper seating of rings (Fig. 17). Fig. 16 Oil Filter Sealing Surface—Typical 1 – SEALING SURFACE 2 – RUBBER GASKET 3 – OIL FILTER Damaged or worn threads can be repaired.

  • Page 154: Valve Timing

    5.9L ENGINE 9 - 153 SERVICE PROCEDURES (Continued) (6) Identify the fluid in the cylinders (i.e. coolant, VALVE GUIDES fuel, oil, etc.). Measure valve stem guide clearance as follows: (7) Make sure all fluid has been removed from the (1) Install Valve Guide Sleeve Tool C-3973 over cylinders.
  • Page 155 9 - 154 5.9L ENGINE SERVICE PROCEDURES (Continued) REAMER SIZES VALVE FACE AND VALVE SEAT ANGLE CHART REAMER O/S VALVE GUIDE SIZE ITEM DESCRIPTION SPECIFICATION 0.076 mm (0.003 in.) 8.026 - 8.052 mm SEAT WIDTH– 1.016 - 1.524 mm (0.316 - 0.317 in.) INTAKE (0.040 - 0.060 in.) 0.381 mm (0.015 in.)

  • Page 156: Measuring Timing Chain Stretch

    5.9L ENGINE 9 - 155 SERVICE PROCEDURES (Continued) Fig. 23 Testing Valve Spring for Compressed Fig. 22 Refacing Valve Seats Length 1 – STONE 1 – TORQUE WRENCH 2 – PILOT 2 – VALVE SPRING TESTER 3 – VALVE SEAT 4 –...

  • Page 157: Pistons-Fitting

    9 - 156 5.9L ENGINE SERVICE PROCEDURES (Continued) (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).

  • Page 158: Connecting Rod Bearings-Fitting

    5.9L ENGINE 9 - 157 SERVICE PROCEDURES (Continued) PISTON MEASUREMENT CHART PISTON A DIA = PISTON BORE SIZE DIAMETER DIAMETER MIN. MAX. MIN. MAX. mm (in.) (in.) (in.) (in.) — — — — 101.580 101.592 101.605 101.618 Fig. 27 Second Compression Ring Identification (3.9992) (3.9997) (4.0002)

  • Page 159: Removal And Installation

    9 - 158 5.9L ENGINE SERVICE PROCEDURES (Continued) Fig. 29 Compression Ring Chamfer Location (Typical) 1 – CHAMFER 2 – TOP COMPRESSION RING Fig. 31 Main Bearing Identification 3 – SECOND COMPRESSION RING 4 – PISTON REMOVAL AND INSTALLATION 5 – CHAMFER ENGINE FRONT MOUNTS REMOVAL—2WD (1) Disconnect the negative cable from the battery.
  • Page 160 5.9L ENGINE 9 - 159 REMOVAL AND INSTALLATION (Continued) Fig. 32 Engine Right Front Insulator Mount—2WD Vehicles Fig. 34 Engine Mount Insulator at Frame 1 – HEAT SHIELD 1 – NUT 2 – INSULATOR 2 – INSULATOR 3 – FRAME 4 –...

  • Page 161: Engine Rear Support

    9 - 160 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 36 Left Engine Mount Insulator and Support Fig. 35 Right Engine Mount Insulator and Support Bracket—4WD Vehicles Bracket—4WD Vehicles 1 – ENGINE SUPPORT BRACKET 1 – ENGINE SUPPORT BRACKET 2 – INSULATOR 2 –...

  • Page 162: Engine Assembly

    5.9L ENGINE 9 - 161 REMOVAL AND INSTALLATION (Continued) Fig. 38 Rear Insulator—2WD Vehicles 1 – ENGINE SUPPORT BRACKET 2 – THROUGH BOLT Fig. 37 Engine Mount Insulator at Frame—4WD 3 – CROSSMEMBER Vehicles 4 – INSULATOR 5 – TRANSMISSION EXTENSION 1 –...
  • Page 163 9 - 162 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) through insulators and support brackets. Separate the engine as follows: • LEFT SIDE —Remove 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.

  • Page 164: Intake Manifold

    5.9L ENGINE 9 - 163 REMOVAL AND INSTALLATION (Continued) INTAKE MANIFOLD INSTALLATION (1) If the plenum pan was removed, position pan REMOVAL gasket and pan. (2) Install plenum pan retaining bolts. (Fig. 41). (1) Disconnect the battery negative cable. (3) Tighten plenum pan mounting bolts as follows: (2) Drain the cooling system.
  • Page 165 9 - 164 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 42 Cross-Over Gaskets 1 – FRONT CROSS-OVER GASKET 2 – REAR CROSS-OVER GASKET place, inspect to make sure seals are in place. Remove alignment studs if used. Fig. 43 Intake Manifold Flange Gasket Alignment (9) The following torque sequence duplicates the 1 –...

  • Page 166: Exhaust Manifold

    5.9L ENGINE 9 - 165 REMOVAL AND INSTALLATION (Continued) EXHAUST MANIFOLD REMOVAL (1) Disconnect the battery negative cable. (2) Raise the vehicle. (3) Remove the exhaust pipe to manifold nuts. (4) Lower the vehicle. (5) Remove three nuts, heat shield and washers from the right side exhaust manifold, if necessary (Fig.

  • Page 167: Rocker Arms And Push Rods

    9 - 166 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Rotate the crankshaft until the “V8” mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No.1 firing position. (2) Install the push rods in the same order as removed.

  • Page 168: Cylinder Head

    5.9L ENGINE 9 - 167 REMOVAL AND INSTALLATION (Continued) CYLINDER HEAD REMOVAL (1) Disconnect the battery negative cable. (2) Drain cooling system Refer to COOLING SYS- TEM. (3) Remove intake manifold-to-generator bracket support rod. Remove the generator. (4) Remove closed crankcase ventilation system. (5) Disconnect the evaporation control system.

  • Page 169: Hydraulic Tappets

    9 - 168 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) (4) Before removing valves, remove any burrs from (7) Install rocker arm. valve stem lock grooves to prevent damage to the (8) Install cylinder head cover. valve guides. Identify valves to ensure installation in (9) Install air cleaner assembly and air inlet hose.

  • Page 170: Timing Chain Cover

    5.9L ENGINE 9 - 169 REMOVAL AND INSTALLATION (Continued) (2) Place installing tool, part of Puller Tool Set C-3688 in position and press the vibration damper onto the crankshaft (Fig. 52). Fig. 53 Removal of Front Crankshaft Oil Seal (3) Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket.

  • Page 171: Timing Chain

    9 - 170 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) (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).
  • Page 172 5.9L ENGINE 9 - 171 REMOVAL AND INSTALLATION (Continued) Fig. 57 Alignment of Timing Marks 1 – TIMING MARKS Fig. 59 Timing Chain Oil Tab Installation 1 – THRUST PLATE FRONT SIDE 2 – CHAIN OIL TAB 3 – THRUST PLATE REAR SIDE Fig.

  • Page 173: Camshaft Bearings

    9 - 172 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) torque. Top edge of tab should be flat against thrust CAMSHAFT BEARINGS plate in order to catch oil for chain lubrication. (5) Place both camshaft sprocket and crankshaft REMOVAL sprocket on the bench with timing marks on exact imaginary center line through both camshaft and NOTE: This procedure requires that the engine is crankshaft bores.
  • Page 174 5.9L ENGINE 9 - 173 REMOVAL AND INSTALLATION (Continued) (4) Hold puller screw and tighten puller nut until bushing is removed. Fig. 65 Burnishing Distributor Driveshaft Bushing 1 – SPECIAL TOOL C-3053 2 – BUSHING Fig. 63 Distributor Driveshaft Bushing Removal 1 –...

  • Page 175: Crankshaft Main Bearings

    9 - 174 5.9L ENGINE 2000 DN Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 CRANKSHAFT MAIN BEARINGS (4) Disconnect distributor cap and position away from cowl. (5) Remove the fan shroud. Refer to COOLING REMOVAL SYSTEM.

  • Page 176: Piston And Connecting Rod Assembly

    5.9L ENGINE 9 - 175 2000 DN Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 INSTALLATION (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.

  • Page 177: Crankshaft

    9 - 176 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION CRANKSHAFT (1) Be sure that compression ring gaps are stag- A crankshaft which has undersize journals will be gered so that neither is in-line with oil ring rail gap. stamped with 1/4 inch letters on the milled flat on (2) Before installing the ring compressor, make the No.3 crankshaft counterweight (Fig.

  • Page 178: Oil Pump

    5.9L ENGINE 9 - 177 REMOVAL AND INSTALLATION (Continued) (7) Remove and discard the crankshaft rear oil seals. (8) Remove and discard the front crankshaft oil seal. INSPECTION OF JOURNALS The crankshaft connecting rod and main journals should be checked for excessive wear, taper and scor- ing.

  • Page 179: Crankshaft Oil Seal-Front

    9 - 178 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) (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 SEAL—FRONT The oil seal can be replaced without removing the timing chain cover provided the cover is not mis-...

  • Page 180: Crankshaft Oil Seals-Rear

    5.9L ENGINE 9 - 179 REMOVAL AND INSTALLATION (Continued) CRANKSHAFT OIL SEALS—REAR (8) To align the bearing cap, use cap slot, align- ment dowel and cap bolts. DO NOT remove excess The service seal is a 2 piece, viton seal. The upper material after assembly.

  • Page 181: Engine Core Oil And Camshaft Plugs

    9 - 180 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) least the 2 main bearing caps forward of the rear allow the sealant to contact the rubber seal. Assem- bearing cap. ble bearing cap to cylinder block immediately after (3) Rotate the new upper seal into the cylinder sealant application.

  • Page 182: Disassembly And Assembly Oil Pump

    5.9L ENGINE 9 - 181 REMOVAL AND INSTALLATION (Continued) Fig. 80 Core Hole Plug Removal Fig. 81 Oil Pressure Relief Valve 1 – CYLINDER BLOCK 1 – OIL PUMP ASSEMBLY 2 – REMOVE PLUG WITH PLIERS 2 – COTTER PIN 3 –...

  • Page 183: Cleaning And Inspection

    9 - 182 5.9L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLE Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore (Fig. 83). (1) Install pump rotors and shaft, using new parts as required. (2) Position the oil pump cover onto the pump body.
  • Page 184 5.9L ENGINE 9 - 183 CLEANING AND INSPECTION (Continued) PISTON MEASUREMENT CHART PISTON A DIA = PISTON BORE SIZE DIAMETER DIAMETER MIN. MAX. MIN. MAX. mm (in.) (in.) (in.) (in.) — — — — 101.580 101.592 101.605 101.618 (3.9992) (3.9997) (4.0002) (4.0007) 101.592...
  • Page 185 9 - 184 5.9L ENGINE CLEANING AND INSPECTION (Continued) Slide outer rotor into pump body. Press rotor to the side with your fingers and measure clearance between rotor and pump body (Fig. 87). If clearance is 0.356 mm (0.014 inch) or more, replace oil pump assembly.

  • Page 186: Cylinder Block

    5.9L ENGINE 9 - 185 CLEANING AND INSPECTION (Continued) CYLINDER BLOCK SPECIFICATIONS CLEANING 5.9L ENGINE SPECIFICATIONS Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. DESCRIPTION SPECIFICATION INSPECTION Engine Type 90° V-8 OHV Examine block for cracks or fractures. Bore and Stroke 101.6 x 90.9 mm The cylinder walls should be checked for out-of-...
  • Page 187 9 - 186 5.9L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Bearing Journal Diameter Bearing Clearance No. 1 50.749 – 50.775 mm #1 Journal 0.013 – 0.038 mm (1.998 – 1.999 in.) (0.0005 – 0.0015 in.) No. 2 50.343 – 50.368 mm Service Limit (1.982 –...
  • Page 188 5.9L ENGINE 9 - 187 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Valves HYDRAULIC TAPPETS Face Angle 43.25° – 43.75° Body Diameter 22.949 – 22.962 mm Head Diameter – Intake 47.752 mm (1.88 in.) (0.9035 – 0.9040 in.) Head Diameter – 41.072 (1.617 in.) Clearance (to bore) 0.0279 –...
  • Page 189 9 - 188 5.9L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION PISTONS Oil Ring (Steel Rails) – 0.447 –0.473 mm Max. Clearance at Top of Skirt 0.013 – 0.038 mm (0.018 – 0.019 in.) (0.0005 – 0.0015 in.) VALVE TIMING Land Clearance (Diam.) 0.508 –...

  • Page 190: Specifications

    5.9L ENGINE 9 - 189 SPECIFICATIONS (Continued) SPECIFICATIONS DESCRIPTION N·m TORQUE CHART 5.9L ENGINE Lbs. Lbs. Rear Insulator to — DESCRIPTION N·m Transmission— Lbs. Lbs. Bolts (4WD) Camshaft Sprocket—Bolt — Rear Insulator Bracket—Bolts — Camshaft Thrust Plate—Bolts — (4WD Automatic) Timing Chain Case Cover—...
  • Page 191 9 - 190 5.9L ENGINE SPECIAL TOOLS (Continued) Engine Support Fixture C-3487–A Dial Indicator C-3339 Valve Spring Compressor MD-998772–A Puller C-3688 Adapter 6633 Puller 1026 Adapter 6716A Crankshaft Damper Removal Insert 8513 Valve Guide Sleeve C-3973 Front Oil Seal Installer 6635...
  • Page 192 5.9L ENGINE 9 - 191 SPECIAL TOOLS (Continued) Cam Bearing Remover/Installer C-3132–A Piston Ring Compressor C-385 Camshaft Holder C-3509 Crankshaft Main Bearing Remover C-3059 Distributor Bushing Puller C-3052 Cylinder Bore Gauge C-119 Distributor Bushing Driver/Burnisher C-3053 Pressure Tester Kit 7700 Bloc–Chek–Kit C-3685–A...

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