Dodge 2000 DURANGO Service Manual page 574

DN
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. lbs.).
(3) Position the oil pan and install the mounting
bolts. Tighten the mounting bolts to 15 N·m (11 ft.
lbs.) in the sequence shown (Fig. 110).
(4) Install structural dust cover.
(5) Install oil filter.
(6) Install front axle. Refer to DIFFERENTIAL
AND DRIVELINE.
(7) Lower vehicle.
(8) Fill engine oil.
(9) Start engine check for leaks.
PISTON AND CONNECTING ROD
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the following components: (Refer to
procedures in this section)
• Oil pan and gasket/windage tray.
• Cylinder head covers.
• Timing chain cover.
• Cylinder head(s).
(3) If necessary, remove top ridge of cylinder bores
with a reliable ridge reamer before removing pistons
from cylinder block. Be sure to keep tops of pis-
tons covered during this operation. Pistons and
connecting rods must be removed from top of cylinder
block. When removing piston and connecting rod
assemblies from the engine, rotate crankshaft so the
each connecting rod is centered in cylinder bore.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods or caps, as damage to
connecting rods could occur
NOTE: Connecting rods and bearing caps are not
interchangeable and should be marked before
removing to ensure correct reassembly.
(4) Mark connecting rod and bearing cap positions
using a permanent ink marker or scribe tool (Fig.
111).
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as engine
damage may occur.
(5) Remove connecting rod cap. Install Special Tool
8507 Connecting Rod Guides into the connecting rod
being removed. Remove piston from cylinder bore.
Repeat this procedure for each piston being removed.
Fig. 111 Identify Connecting Rod to Cylinder
Position—Typical
CAUTION: Care must be taken not to nick crank-
shaft journals, as engine damage may occur
(6) Immediately after piston and connecting rod
removal, install bearing cap on the mating connect-
ing rod to prevent damage to the fractured cap and
rod surfaces.
(7) Carefully remove piston rings from piston(s),
starting from the top ring down.
PISTON RINGS—INSTALLATION
(1) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Ensure No. 2 ring is installed with
manufacturers I.D. mark (Dot) facing up, towards top
of the piston.
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.
(2) Install the oil ring expander.
(3) Install upper side rail (Fig. 112) by placing one
end between the piston ring groove and the expander
ring. Hold end firmly and press down the portion to
be installed until side rail is in position. Repeat this
step for the lower side rail.
(4) Install No. 2 intermediate piston ring using a
piston ring installer (Fig. 113).
(5) Install No. 1 upper piston ring using a piston
ring installer (Fig. 113).
(6) Position piston ring end gaps as shown in (Fig.
114). It is important that expander ring gap is at
least 45° from the side rail gaps, but not on the pis-
ton pin center or on the thrust direction.
INSTALLATION
(1) Before installing piston and connecting rod
assemblies in to the bore, ensure all rings are in
position shown in (Fig. 114).
4.7L ENGINE 9 - 65