DN ENGINE 9-1

ENGINE
TABLE OF CONTENTS

page page

4.7L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5.9L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

5.2L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4.7L ENGINE

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION SERVICE PROCEDURES

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FORM-IN-PLACE GASKETS. . . . . . . . . . . . . . . . . 15
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . 3 ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . 5 REPAIR DAMAGED OR WORN THREADS . . . . . . 17
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CYLINDER BORE—HONING . . . . . . . . . . . . . . . . 18
PISTON AND CONNECTING ROD . . . . . . . . . . . . . 5 HYDROSTATIC LOCK . . . . . . . . . . . . . . . . . . . . . 18
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . 5 VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 19
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ENGINE TIMING—VERIFICATION . . . . . . . . . . . . 19
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TIMING CHAIN—MEASURING WEAR . . . . . . . . . 22
VALVE STEM SEAL . . . . . . . . . . . . . . . . . . . . . . . . 5 PISTONS—FITTING . . . . . . . . . . . . . . . . . . . . . . . 22
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 PISTON RINGS—FITTING . . . . . . . . . . . . . . . . . . 24
HYDRAULIC LASH ADJUSTER . . . . . . . . . . . . . . . 6 CONNECTING ROD BEARINGS—FITTING . . . . . 25
TIMING DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . 6 CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . . 27
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL AND INSTALLATION
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ENGINE MOUNTS—LEFT AND RIGHT. . . . . . . . . 28
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . 6 ENGINE MOUNT—REAR . . . . . . . . . . . . . . . . . . . 29
OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 STRUCTURAL COVER. . . . . . . . . . . . . . . . . . . . . 30
STRUCTURAL DUST COVER . . . . . . . . . . . . . . . . 7 ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 31
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 7 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 35
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 7 EXHAUST MANIFOLDS . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . 38
ENGINE DIAGNOSIS—INTRODUCTION. . . . . . . . . 7 ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SERVICE DIAGNOSIS—PERFORMANCE . . . . . . . 8 CYLINDER HEADS. . . . . . . . . . . . . . . . . . . . . . . . 41
SERVICE DIAGNOSIS—MECHANICAL. . . . . . . . . 10 VALVE SPRINGS AND SEALS . . . . . . . . . . . . . . . 46
SERVICE DIAGNOSIS—LUBRICATION. . . . . . . . . 11 HYDRAULIC LASH ADJUSTER . . . . . . . . . . . . . . 46
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 11 CRANKSHAFT DAMPER . . . . . . . . . . . . . . . . . . . 47
CYLINDER COMPRESSION PRESSURE TEST . . 11 TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . . 48
CYLINDER HEAD GASKET FAILURE TIMING CHAIN AND SPROCKETS . . . . . . . . . . . . 49
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 IDLER SHAFT—TIMING DRIVE . . . . . . . . . . . . . . 55
CYLINDER COMBUSTION PRESSURE CAMSHAFTS—IN VEHICLE . . . . . . . . . . . . . . . . . 56
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 12 CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . . 61
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . 13 OIL PAN 4X2 VEHICLE. . . . . . . . . . . . . . . . . . . . . 61
REAR SEAL AREA LEAKS—INSPECTION . . . . . . 14 OIL PAN 4X4 VEHICLE. . . . . . . . . . . . . . . . . . . . . 64
HYDRAULIC LASH ADJUSTER NOISE PISTON AND CONNECTING ROD . . . . . . . . . . . . 65
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CHECKING ENGINE OIL PRESSURE. . . . . . . . . . 15 FLEXPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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 9-2 4.7L ENGINE DN

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 CYLINDER HEADS. . . . . . . . . . . . . . . . . . . . . . . . 75

ENGINE OIL PRESSURE SENDING UNIT . . . . . . 70 PISTON AND CONNECTING ROD . . . . . . . . . . . . 76
CRANKSHAFT OIL SEAL—FRONT. . . . . . . . . . . . 70 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
CRANKSHAFT OIL SEAL—REAR. . . . . . . . . . . . . 73 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
ENGINE CORE PLUGS . . . . . . . . . . . . . . . . . . . . 74 CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 76
DISASSEMBLY AND ASSEMBLY SPECIFICATIONS
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
CLEANING AND INSPECTION TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 75 SPECIAL TOOLS
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 75 4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

DESCRIPTION AND OPERATION cylinder block is made up of two different compo-

nents; the first component is the cylinder bore and
ENGINE upper block, the second component is the bedplate
that comprises the lower portion of the cylinder block
DESCRIPTION and houses the lower half of the crankshaft main
The 4.7 liter (287 CID) eight-cylinder engine is an bearings. The cylinders are numbered from front to
90° single overhead camshaft engine. The cast iron rear with the left bank being numbered 1,3,5 and 7,
and the right bank being numbered 2,4,6 and 8. The

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 DN 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.

OPERATION
Oil from the oil pan is pumped by a gerotor type oil
pump directly mounted to the crankshaft nose. Oil
pressure is controlled by a relief valve mounted
inside the oil pump housing. For lubrication flow
refer to (Fig. 2).
The camshaft exhaust valve lobes and rocker arms
are lubricated through a small hole in the rocker
arm; oil flows through the lash adjuster then through
the rocker arm and onto the camshaft lobe. Due to
the orentation of the rocker arm, the camshaft intake
lobes are not lubed in the same manner as the
exhaust lobes. The intake lobes are lubed through Fig. 1 Engine Identification Location.
internal passages in the camshaft. Oil flows through 1 – VEHICLE VIN NUMBER LOCATION
a bore in the number 3 camshaft bearing bore, and 2 – CYLINDER BLOCK RIGHT HAND SIDE
as the camshaft turns, a hole in the camshaft aligns 3 – CYLINDER BORE #2
with the hole in the camshaft bore allowing engine
oil to enter the camshaft tube. The oil then exits intake lobes, lubricating the lobes and the rocker
through 1.6mm (0.063 in.) holes drilled into the arms.

ENGINE LUBRICATION FLOW CHART—BLOCK: TABLE 1

FROM TO
Oil Pickup Tube Oil Pump
Oil Pump Oil Filter
Oil Filter Block Main Oil Gallery
Block Main Oil Gallery 1. Crankshaft Main Journal
2. Left Cylinder Head*
3. Right Cylinder Head*
Crankshaft Main Journals Crankshaft Rod Journals
Crankshaft Number One Main Journal 1.Front Timing Chain Idler Shaft
2. Both Secondary Chain Tensioners
Left Cylinder Head See Table 2
Right Cylinder Head See Table 2
* The cylinder head
gaskets have an oil restricter to control oil flow to the cylinder heads.

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 9-4 4.7L ENGINE DN
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 – TO LEFT CYLINDER HEAD 9 – TO RIGHT CYLINDER HEAD
4 – OIL FEED TO IDLER SHAFT 10 – CYLINDER BLOCK MAIN GALLERY
5 – OIL PUMP OUTLET TO BLOCK 11 – OIL FEED TO BOTH SECONDARY TENSIONERS
6 – OIL PUMP

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 DN 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 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 LATE BUILD

The pistons are made of high strength aluminum
DESCRIPTION alloy. The top ring groove and crown are Not anod-
The cylinder block is made of cast iron. The block ized, instead the top ring is coated with an anti-scuff
is a closed deck design with the left bank forward. To coating to reduce friction on the top ring. The piston
provide high rigidity and improved NVH an skirts are coated with a solid lubricant (Molykote) to
enhanced compacted graphite bedplate is bolted to reduce friction and provide scuff resistance. The con-
the block. The block design allows coolant flow necting rods are made of forged powdered metal,
between the cylinders bores, and an internal coolant with a “fractured cap” design. A pressed fit piston pin
bypass to a single poppet inlet thermostat is included is used to attach the piston and connecting rod.
in the cast aluminum front cover.
CRANKSHAFT CYLINDER HEAD
DESCRIPTION DESCRIPTION
The crankshaft is constructed of nodular cast iron. The cylinder heads are made of an aluminum alloy.
The crankshaft is a crosshaped four throw design The cylinder head features two valves per cylinder
with eight counterweights for balancing purposes. with pressed in powdered metal valve guides. The
The crankshaft is supported by five select main bear- cylinder heads also provide enclosures for the timing
ings with the number three serving as the thrust chain drain, necessitating unique left and right cylin-
washer location. The main journals of the crankshaft der heads.
are cross drilled to improve rod bearing lubrication.
The number eight counterweight has provisions for VALVE GUIDES
crankshaft position sensor target wheel mounting. DESCRIPTION
The select fit main bearing markings are located on
The valve guides are made of powered metal and
the rear side of the target wheel. The crankshaft oil
are pressed into the cylinder head. The guides are
seals are one piece design. The front oil seal is
not replaceable or serviceable, and valve guide ream-
retained in the timing chain cover, and the rear seal
ing is not recommended. If the guides are worn
is pressed in to a bore formed by the cylinder block
beyond acceptable limits, replace the cylinder heads.
and the bedplate assembly.
PISTON AND CONNECTING ROD VALVES
DESCRIPTION DESCRIPTION
CAUTION: Do not use a metal stamp to mark con- The valves are made of heat resistant steel and
necting rods as damage may result, instead use ink have chrome plated stems to prevent scuffing. Each
or a scratch awl. 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
EARLY BUILD valve rotation.
The pistons are made of a high strength aluminum
alloy with an anodized top ring groove and crown. Piston VALVE STEM SEAL
skirts are coated with a solid lubricant (Molykote) to DESCRIPTION
reduce friction and provide scuff resistance. The connect- The valve stem seals are made of rubber and incor-
ing rods are made of forged powdered metal, with a porate an integral steel valve spring seat. The inte-
“fractured cap” design. A pressed fit piston pin is used to gral garter spring maintains consistent lubrication
attach the piston and connecting rod. control to the valve stems.

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 9-6 4.7L ENGINE DN
DESCRIPTION AND OPERATION (Continued)

VALVE SPRING There are two secondary drive chains, both are
inverted tooth type, one to drive the camshaft in each
DESCRIPTION SOHC cylinder head. There are no shaft speed
The valve springs are made from high strength changes in the secondary chain drive system. Each
chrome silicon steel. The springs are common for secondary chain drives a thirty tooth cam sprocket
intake and exhaust applications. The valve spring directly from the thirty tooth sprocket on the idler
seat is integral with the valve stem seal, which is a sprocket assembly. A fixed chain guide and a hydrau-
positive type seal to control lubrication. lic oil damped tensioner are used to maintain tension
in each secondary chain system. The hydraulic ten-
HYDRAULIC LASH ADJUSTER sioners for the secondary chain systems are fed pres-
surized oil from oil reservoir pockets in the block.
DESCRIPTION Each tensioner also has a mechanical ratchet system
Valve lash is controlled by hydraulic lash adjusters that limits chain slack if the tensioner piston bleeds
that are stationary mounted in the cylinder heads. down after engine shut down. The tensioner arms
The lash adjusters have a hole in the ball plunger and guides also utilize nylon wear faces for low fric-
that feeds oil through the rocker arm squirt holes for tion and long wear. The secondary timing chains
rocker arm roller and camshaft lobe lubrication. receive lubrication from a small orifice in the ten-
sioners. This orifice is protected from clogging by a
TIMING DRIVE SYSTEM fine mesh screen which is located on the back of the
hydraulic tensioners.
DESCRIPTION
The timing drive system has been designed to pro- CAMSHAFT
vide quiet performance and reliability to support a
non-free wheeling engine. Specifically the intake DESCRIPTION
valves are non-free wheeling and can be easily dam- The camshafts consist of powdered metal steel
aged with forceful engine rotation if camshaft-to- lobes which are sinter-bonded to a steel tube. A steel
crankshaft timing is incorrect. The timing drive post or nose piece is friction-welded to the steel cam-
system consists of a primary chain and two second- shaft tube. Five bearing journals are machined into
ary timing chain drives. the camshaft, four on the steel tube and one on the
steel nose piece. Camshaft end play is controlled by
OPERATION two thrust walls that border the nose piece journal.
The primary timing chain is a single inverted tooth Engine oil enters the hollow camshafts at the third
type. The primary chain drives the large fifty tooth journal and lubricates every intake lobe rocker
idler sprocket directly from a 25 tooth crankshaft through a drilled passage in the intake lobe.
sprocket. Primary chain motion is controlled by a
pivoting leaf spring tensioner arm and a fixed guide. ROCKER ARM
The arm and the guide both use nylon plastic wear
faces for low friction and long wear. The primary DESCRIPTION
chain receives oil splash lubrication from the second- The rocker arms are steel stampings with an inte-
ary chain drive and oil pump leakage. The idler gral roller bearing. The rocker arms incorporate a 2.8
sprocket assembly connects the primary and second- mm (0.11 inch) oil hole in the lash adjuster socket for
ary chain drives. The idler sprocket assembly con- roller and camshaft lubrication.
sists of two integral thirty tooth sprockets and a fifty
tooth sprocket that is splined to the assembly. The CYLINDER HEAD COVER
spline joint is a non – serviceable press fit anti rattle
type. A spiral ring is installed on the outboard side of DESCRIPTION
the fifty tooth sprocket to prevent spline disengage- The cylinder head covers are made of die cast mag-
ment. The idler sprocket assembly spins on a station- nesium, and are not interchangeable from side-to-
ary idler shaft. The idler shaft is press-fit into the side. It is imperative that nothing rest on the
cylinder block. A large washer on the idler shaft bolt cylinder head covers. Prolonged contact with other
and the rear flange of the idler shaft are used to con- items may wear a hole in the cylinder head cover.
trol sprocket thrust movement. Pressurized oil is
routed through the center of the idler shaft to pro-
vide lubrication for the two bushings used in the
idler sprocket assembly.

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 DN 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
DESCRIPTION graphite exhaust manifold gasket is used to improve
The engine oil pan is made of laminated steel and sealing to the cylinder head. The exhaust manifolds
has a single plane sealing surface. The sandwich are covered by a three layer laminated heat shield
style oil pan gasket has an integrated windage tray for thermal protection and noise reduction. The heat
and steel carrier. The sealing area of the gasket is shields are fastened with a torque prevailing nut
molded with rubber and is designed to be reused as that is backed off slightly to allow for the thermal
long as the gasket is not cut, torn or ripped. expansion of the exhaust manifold.

STRUCTURAL DUST COVER DIAGNOSIS AND TESTING

DESCRIPTION ENGINE DIAGNOSIS—INTRODUCTION
The structural dust cover is made of die cast alu-
Engine diagnosis is helpful in determining the
minum and joins the lower half of the transmission
causes of malfunctions not detected and remedied by
bell housing to the engine bedplate.
routine maintenance.
These malfunctions may be classified as either per-
OPERATION
formance (e.g., engine idles rough and stalls) or
The structural cover provides additional power-
mechanical (e.g., a strange noise).
train stiffness and reduces noise and vibration.
Refer to the Service Diagnosis—Performance chart
and the Service Diagnosis—Mechanical chart for pos-
INTAKE MANIFOLD sible causes and corrections of malfunctions. Refer to
Group 14, Fuel System for the fuel system diagnosis.
DESCRIPTION Additional tests and diagnostic procedures may be
The intake manifold is made of a composite mate-
necessary for specific engine malfunctions that can
rial and features long runners which maximizes low
not be isolated with the Service Diagnosis charts.
end torque. The intake manifold uses single plane
Information concerning additional tests and diagno-
sealing which consist of eight individual press in
sis is provided within the following diagnosis:
place port gaskets to prevent leaks. Eight studs and
• Cylinder Compression Pressure Test.
two bolts are used to fasten the intake to the head.
• Cylinder Combustion Pressure Leakage Test.
• Engine Cylinder Head Gasket Failure Diagnosis.
EXHAUST MANIFOLD • Intake Manifold Leakage Diagnosis.
DESCRIPTION
The exhaust manifolds are log style with a pat-
ented flow enhancing design to maximize perfor-

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 9-8 4.7L ENGINE DN
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.
3. Faulty starter. 3. Refer to Group 8A, Battery/
Starter/ Charging System
Diagnostics.
4. Moisture on ignition wires and 4. Wipe wires and cap clean and
distributor cap. dry.
5. Faulty ignition cables. 5. Replace as necessary.
6. Faulty coil or control unit. 6. Refer to Group 8D, Ignition
System.
7. Incorrect spark plug gap. 7. Refer to Group 8D, Ignition
System.
8. Incorrect ignition timing. 8. Refer to Group 8D, Ignition
System.
9. Dirt or water in fuel system. 9. Clean system and replace fuel
filter.
10. Faulty fuel pump, relay or 10. Refer to Group 14, Fuel System.
wiring.

ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low. 1. Refer to Group 14, Fuel System.

2. Idle mixture to lean or to rich. 2. Refer to Group 14, Fuel System.

3. Vacuum leak. 3. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.
4. Worn or burned distributor rotor. 4. Replace distributor rotor.
5. Incorrect ignition wiring. 5. Install correct wiring.
6. Faulty coil. 6. Refer to Group 8D, Ignition
System.
7. EGR valve leaking. 7. Refer to Group 25, Emissions
Control System.
8. Incorrect cam timing. 8. Refer to Valve Timing in this
section.

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 DN 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. Refer to Group 8D, Ignition
System.
4. Dirty or incorrectly gapped spark 4. Refer to Group 8D, Ignition
plugs. System.
5. Dirt or water in fuel system. 5. Clean system and replace fuel
filter.
6. Faulty fuel pump. 6. Refer to Group 14, Fuel System.
7. Blown cylinder head gasket. 7. Replace cylinder head gasket.
8. Low compression. 8. Test compression, repair as
necessary.
9. Burned, warped or pitted valves. 9. Replace as necessary.
10. Plugged or restricted exhaust 10. Inspect and replace as
system. necessary.
11. Faulty ignition cables. 11. Replace as necessary.
12. Faulty coil. 12. Refer to Group 8D, Ignition
System.
13. Incorrect cam timing. 13. Refer to Valve Timing in this
section.

ENGINE MISSES ON 1. Spark plugs dirty or incorrectly 1. Refer to Group 8D, Ignition
ACCELERATION gapped. System.

2. Incorrect ignition timing. 2. Refer to Group 8D, Ignition

System.
3. Dirt in fuel system. 3. Clean fuel system.
4. Burned, warped or pitted valves. 4. Replcae as necessary.
5. Faulty coil. 5. Refer to Group 8D, Ignition
System.
6. Incorrect cam timing. 6. Refer to Valve Timing in this
section.

ENGINE MISSES AT HIGH SPEED 1. Spark plugs dirty or incorrectly 1. Refer to Group 8D, Ignition
gapped. System.
2. Worn Distributor Shaft. 2. Refer to Group 8D, Ignition
System.
3. Worn or burned distributor rotor. 3. Replace distributor rotor.
4. Faulty coil. 4. Refer to Group 8D, Ignition
System.
5. Incorrect ignition timing. 5. Refer to Group 8D, Ignition
System.
6. Dirt or water in fuel system. 6. Clean system and replace fuel
filter.
7. Incorrect cam timing. 7. Refer to Valve Timing in this
section.

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 9 - 10 4.7L ENGINE DN
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. Low oil pressure. 3. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
4. Dirt in lash adjusters. 4. Clean lash adjusters.
5. Bent push rods. 5. Replace as necessary.
6. Worn rocker arms. 6. Replace as necessary.
7. Worn tappets 7. Replace as necessary.
8. Worn valve guides. 8. Refer to Valve Service in this
section.
9. Excessive runout of valve seats 9. Service valves and valve seats.
on valve faces. Refer to Valve Service in this
section.

CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Refer to Group 0, Lubrication and
maintenance.

2. Low oil pressure. 2. Refer to Group 0, Lubrication and

maintenance.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Connecting rod journal 5. Service or replace crankshaft.
out-of-round.
6. Misaligned connecting rods. 6. Replace bent connecting rods.

MAIN BEARING NOISE 1. Insufficient oil supply. 1. Refer to Group 0, Lubrication and
maintenance.
2. Low oil pressure. 2. Refer to Group 0, Lubrication and
maintenance.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Excessive end play. 5. Check No. 3 main bearing for
wear on flanges.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque 7. Tighten to correct torque
converter.

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 DN 4.7L ENGINE 9 - 11
DIAGNOSIS AND TESTING (Continued)

SERVICE DIAGNOSIS—LUBRICATION

CONDITION POSSIBLE CAUSES CORRECTION

OIL LEAKS 1. Gaskets and O-Rings. 1.

(a) Misaligned or damaged. (a) Replace as necessary.

(b) Loose fasteners, broken or (b) Tighten fasteners, Repair or
porous metal parts. replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary.
3. Crankshaft seal flange. 3. Polish or replace crankshaft.
Scratched, nicked or grooved.
4. Oil pan flange cracked. 4. Replace oil pan.
5. Timing chain cover seal, 5. Replace seal.
damaged or misaligned.
6. Scratched or damaged vibration 6. Polish or replace damper.
damper hub.

OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.

2. Faulty oil pressure sending unit. 2. Replace sending unit.

3. Low oil pressure. 3. Check pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter.
5. Worn oil pump. 5. Replace as necessary.
6. Thin or diluted oil. 6. Change oil and filter.
7. Excessive bearing clearance. 7. Replace as necessary.
8. Oil pump relief valve stuck. 8. Clean or replace relief valve.
9. Oil pump suction tube loose or 9. Replace as necessary.
damaged.

OIL PUMPING AT RINGS; SPARK 1. Worn or damaged rings. 1. Hone cylinder bores and replace
PLUGS FOULING rings.
2. Carbon in oil ring slots. 2. Replace rings.
3. Incorrect ring size installed. 3. Replace rings.
4. Worn valve guides. 4. Ream guides and replace valves.
5. Leaking intake gasket. 5. Replace intake gaskets.
6. Leaking valve guide seals. 6. Replace valve guide seals.

INTAKE MANIFOLD LEAKAGE DIAGNOSIS (2) Spray a small stream of water at the suspected
An intake manifold air leak is characterized by leak area.
lower than normal manifold vacuum. Also, one or (3) If a change in RPM is observed the area of the
more cylinders may not be functioning. suspected leak has been found.
(4) Repair as required.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A CYLINDER COMPRESSION PRESSURE TEST
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR The results of a cylinder compression pressure test
HANDS NEAR THE PULLEYS, BELTS OR THE FAN. can be utilized to diagnose several engine malfunc-
DO NOT WEAR LOOSE CLOTHING. tions.
Ensure the battery is completely charged and the
(1) Start the engine. engine starter motor is in good operating condition.

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 9 - 12 4.7L ENGINE DN
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
air. PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
(2) Remove the spark plugs. SIVE PRESSURE BUILT UP, BY CONTINUOUS
(3) Secure the throttle in the wide-open position. ENGINE OPERATION, MUST BE RELEASED TO A
(4) Disable the fuel system. (Refer to Group 14, SAFE PRESSURE POINT. NEVER PERMIT PRES-
Fuel System for the correct procedure) SURE TO EXCEED 138 kPa (20 psi).
(5) Disconnect the ignition coil.
(6) Insert a compression pressure gauge and rotate Install Cooling System Tester 7700 or equivalent to
the engine with the engine starter motor for three pressure cap neck. Start the engine and observe the
revolutions. tester’s pressure gauge. If gauge pulsates with every
(7) Record the compression pressure on the 3rd power stroke of a cylinder a combustion pressure
revolution. Continue the test for the remaining cylin- leak is evident.
ders.
Refer to Engine Specifications for the correct CHEMICAL TEST METHOD
engine compression pressures. Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
CYLINDER HEAD GASKET FAILURE DIAGNOSIS equivalent. Perform test following the procedures
A cylinder head gasket leak can be located between supplied with the tool kit.
adjacent cylinders or between a cylinder and the
adjacent water jacket. CYLINDER COMBUSTION PRESSURE LEAKAGE
• Possible indications of the cylinder head gasket TEST
leaking between adjacent cylinders are: The combustion pressure leakage test provides an
• Loss of engine power accurate means for determining engine condition.
• Engine misfiring Combustion pressure leakage testing will detect:
• Poor fuel economy • Exhaust and intake valve leaks (improper seat-
• Possible indications of the cylinder head gasket ing).
leaking between a cylinder and an adjacent water • Leaks between adjacent cylinders or into water
jacket are: jacket.
• Engine overheating • Any causes for combustion/compression pressure
• Loss of coolant loss.
• Excessive steam (white smoke) emitting from (1) Check the coolant level and fill as required. DO
exhaust NOT install the radiator cap.
• Coolant foaming (2) Start and operate the engine until it attains
normal operating temperature, then turn the engine
CYLINDER-TO-CYLINDER LEAKAGE TEST OFF.
To determine if an engine cylinder head gasket is (3) Remove the spark plugs.
leaking between adjacent cylinders, follow the proce- (4) Remove the oil filler cap.
dures in Cylinder Compression Pressure Test in this (5) Remove the air cleaner.
section. An engine cylinder head gasket leaking (6) Calibrate the tester according to the manufacturer’s
between adjacent cylinders will result in approxi- instructions. The shop air source for testing should main-
mately a 50–70% reduction in compression pressure. tain 483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maxi-
mum and 552 kPa (80 psi) recommended.
CYLINDER-TO-WATER JACKET LEAKAGE TEST (7) Perform the test procedures on each cylinder
according to the tester manufacturer’s instructions.
WARNING: USE EXTREME CAUTION WHEN THE While testing, listen for pressurized air escaping
ENGINE IS OPERATING WITH COOLANT PRES- through the throttle body, tailpipe and oil filler cap
SURE CAP REMOVED. opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
VISUAL TEST METHOD
FOR EXAMPLE: At 552 kPa (80 psi) input pres-
With the engine cool, remove the coolant pressure sure, a minimum of 414 kPa (60 psi) should be main-
cap. Start the engine and allow it to warm up until tained in the cylinder.
thermostat opens. Refer to the Cylinder Combustion Pressure Leak-
If a large combustion/compression pressure leak age Test Diagnosis chart.
exists, bubbles will be visible in the coolant.

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 DN 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.
TAILPIPE seated properly Reface or replace, as necessary
AIR ESCAPES THROUGH Head gasket leaking or cracked Remove cylinder head and inspect.
RADIATOR cylinder head or block Replace defective part
MORE THAN 50% LEAKAGE Head gasket leaking or crack in Remove cylinder head and inspect.
FROM ADJACENT CYLINDERS cylinder head or block between Replace gasket, head, or block as
adjacent cylinders necessary
MORE THAN 25% LEAKAGE AND Stuck or broken piston rings; Inspect for broken rings or piston.
AIR ESCAPES THROUGH OIL cracked piston; worn rings and/or Measure ring gap and cylinder
FILLER CAP OPENING ONLY cylinder wall diameter, taper and out-of-round.
Replace defective part as necessary

ENGINE OIL LEAK INSPECTION (4) Gradually apply air pressure from 1 psi to 2.5
Begin with a thorough visual inspection of the psi maximum while applying soapy water at the sus-
engine, particularly at the area of the suspected leak. pected source. Adjust the regulator to the suitable
If an oil leak source is not readily identifiable, the test pressure that provide the best bubbles which
following steps should be followed: will pinpoint the leak source. If the oil leak is
(1) Do not clean or degrease the engine at this detected and identified, repair per service manual
time because some solvents may cause rubber to procedures.
swell, temporarily stopping the leak. (5) If the leakage occurs at the rear oil seal area,
(2) Add an oil soluble dye (use as recommended by refer to the section, Inspection for Rear Seal Area
manufacturer). Start the engine and let idle for Leak.
approximately 15 minutes. Check the oil dipstick to (6) If no leaks are detected, turn off the air supply
make sure the dye is thoroughly mixed as indicated and remove the air hose and all plugs and caps.
with a bright yellow color under a black light. Install the PCV valve and breather cap hose.
(3) Using a black light, inspect the entire engine (7) Clean the oil off the suspect oil leak area using
for fluorescent dye, particularly at the suspected area a suitable solvent. Drive the vehicle at various
of oil leak. If the oil leak is found and identified, speeds approximately 24 km (15 miles). Inspect the
repair per service manual instructions. engine for signs of an oil leak by using a black light.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and INSPECTION FOR REAR SEAL AREA LEAKS
repeat inspection. Since it is sometimes difficult to determine the
(4) If the oil leak source is not positively source of an oil leak in the rear seal area of the
identified at this time, proceed with the air leak engine, a more involved inspection is necessary. The
detection test method. following steps should be followed to help pinpoint
the source of the leak.
Air Leak Detection Test Method If the leakage occurs at the crankshaft rear oil seal
(1) Disconnect the breather cap to air cleaner hose area:
at the breather cap end. Cap or plug breather cap (1) Disconnect the battery.
nipple. (2) Raise the vehicle.
(2) Remove the PCV valve from the cylinder head (3) Remove torque converter or clutch housing
cover. Cap or plug the PCV valve grommet. cover and inspect rear of block for evidence of oil.
(3) Attach an air hose with pressure gauge and Use a black light to check for the oil leak:
regulator to the dipstick tube. (a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
CAUTION: Do not subject the engine assembly to (b) Where leakage tends to run straight down,
more than 20.6 kpa (3 PSI) of test pressure. possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil

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 9 - 14 4.7L ENGINE DN
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.
case as outlined in the, Inspection (Engine oil Leaks
in general) CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
CAUTION: Do not exceed 20.6 kPa (3 psi). scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
(5) If the leak is not detected, very slowly turn the seal.
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while (6) For bubbles that remain steady with shaft
slowly turning the crankshaft, it is possible the rotation, no further inspection can be done until dis-
crankshaft seal surface is damaged. The seal area on assembled. Refer to the service Diagnosis—Mechani-
the crankshaft could have minor nicks or scratches cal, under the Oil Leak row, for components
that can be polished out with emery cloth. inspections on possible causes and corrections.
(7) After the oil leak root cause and appropriate
CAUTION: Use extreme caution when crankshaft corrective action have been identified, Refer to Group
polishing is necessary to remove minor nicks and 9, Engines—Crankshaft Rear Oil Seals, for proper
scratches. The crankshaft seal flange is especially replacement procedures.
machined to complement the function of the rear oil
seal. HYDRAULIC LASH ADJUSTER NOISE
(6) For bubbles that remain steady with shaft DIAGNOSIS
rotation, no further inspection can be done until dis- A tappet-like noise may be produced from several
assembled. items. Check the following items.
(1) Engine oil level too high or too low. This may
REAR SEAL AREA LEAKS—INSPECTION cause aerated oil to enter the adjusters and cause
Since it is sometimes difficult to determine the them to be spongy.
source of an oil leak in the rear seal area of the (2) Insufficient running time after rebuilding cylin-
engine, a more involved inspection is necessary. The der head. Low speed running up to 1 hour may be
following steps should be followed to help pinpoint required.
the source of the leak. (3) Turn engine off and let set for a few minutes
If the leakage occurs at the crankshaft rear oil seal before restarting. Repeat this several times after
area: engine has reached normal operating temperature.
(1) Disconnect the battery. (4) Low oil pressure.
(2) Raise the vehicle. (5) The oil restrictor in cylinder head gasket or the
(3) Remove torque converter or clutch housing oil passage to the cylinder head is plugged with
cover and inspect rear of block for evidence of oil. debris.
Use a black light to check for the oil leak: (6) Air ingested into oil due to broken or cracked
(a) Circular spray pattern generally indicates oil pump pick up.
seal leakage or crankshaft damage. (7) Worn valve guides.
(b) Where leakage tends to run straight down, (8) Rocker arm ears contacting valve spring
possible causes are a porous block, distributor seal, retainer.
camshaft bore cup plugs, oil galley pipe plugs, oil (9) Rocker arm loose, adjuster stuck or at maxi-
filter runoff, and main bearing cap to cylinder mum extension and still leaves lash in the system.
block mating surfaces. See Group 9, Engines, for (10) Faulty lash adjuster.
proper repair procedures of these items. a. Check lash adjusters for sponginess while
(4) If no leaks are detected, pressurized the crank- installed in cylinder head and cam on camshaft at
case as outlined in the section, Inspection (Engine oil base circle. Depress part of rocker arm over adjuster.
Leaks in general) Normal adjusters should feel very firm. Spongy
adjusters can be bottomed out easily.
CAUTION: Do not exceed 20.6 kPa (3 psi). b. Remove suspected lash adjusters, and replace.
c. Before installation, make sure adjusters are at
(5) If the leak is not detected, very slowly turn the least partially full of oil. This can be verified by little
crankshaft and watch for leakage. If a leak is or no plunger travel when lash adjuster is depressed.
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the

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 DN 4.7L ENGINE 9 - 15
DIAGNOSIS AND TESTING (Continued)

CHECKING ENGINE OIL PRESSURE have different properties and cannot be used inter-
(1) Remove oil pressure sending unit (Fig. 3) and changeably.
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. Moisture
in the air causes the sealant material to cure. This
material is normally used on flexible metal flanges.
It has a shelf life of a year and will not properly cure
if over aged. Always inspect the package for the expi-
ration date before use.

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. DO NOT use
on flexible metal flanges.

SURFACE PREPARATION
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some
instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
Fig. 3 Oil Pressure Sending Unit may also be lightly tapped into the joint but care
1 – BELT
must be taken not to damage the mating surfaces.
2 – OIL PRESSURE SENSOR
3 – OIL FILTER
Scrape or wire brush all gasket surfaces to remove
4 – ELEC. CONNECTOR all loose material. Inspect stamped parts to ensure
gasket rails are flat. Flatten rails with a hammer on
a flat plate, if required. Gasket surfaces must be free
(2) Run engine until thermostat opens. of oil and dirt. Make sure the old gasket material is
(3) Oil Pressure: removed from blind attaching holes.
• Curb Idle—25 Kpa (4 psi) minimum
• 3000 rpm—170 - 550 KPa (25 - 80 psi) GASKET APPLICATION
(4) If oil pressure is 0 at idle, shut off engine. Assembling parts using a form-in-place gasket
Check for a clogged oil pick-up screen or a pressure requires care.
relief valve stuck open. Mopar Silicone Rubber Adhesive Sealant should be
applied in a continuous bead approximately 3 mm
(0.12 inch) in diameter. All mounting holes must be
SERVICE PROCEDURES
circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4
inch) drop is placed in the center of the gasket con-
FORM-IN-PLACE GASKETS tact area. Uncured sealant may be removed with a
There are several places where form-in-place gas-
shop towel. Components should be torqued in place
kets are used on the engine. DO NOT use form-in-
while the sealant is still wet to the touch (within 10
place gasket material unless specified. Care
minutes). The use of a locating dowel is recom-
must be taken when applying form-in-place gaskets.
mended during assembly to prevent smearing the
Bead size, continuity and location are of great impor-
material off location.
tance. Too thin a bead can result in leakage while too
Mopar Gasket Maker should be applied sparingly
much can result in spill-over. A continuous bead of
to one gasket surface. The sealant diameter should
the proper width is essential to obtain a leak-free
be 1.00 mm (0.04 inch) or less. Be certain the mate-
joint.
rial surrounds each mounting hole. Excess material
Two types of form-in-place gasket materials are
can easily be wiped off. Components should be
used in the engine area (Mopar Silicone Rubber
torqued in place within 15 minutes. The use of a
Adhesive Sealant and Mopar Gasket Maker). Each

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 9 - 16 4.7L ENGINE DN
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.
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR CONTAINER IDENTIFICATION
REPEATED SKIN CONTACT WITH ENGINE OIL. Standard engine oil identification notations have
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY been adopted to aid in the proper selection of engine
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO oil. The identifying notations are located on the label
YOUR HEALTH. THOROUGHLY WASH EXPOSED of engine oil plastic bottles and the top of engine oil
SKIN WITH SOAP AND WATER. DO NOT WASH cans (Fig. 5).
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.

ENGINE OIL SPECIFICATION

CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
Fig. 5 Engine Oil Container Standard Notations
OIL LEVEL INDICATOR (DIPSTICK)
API SERVICE GRADE CERTIFIED The engine oil level indicator is located at the right
Use an engine oil that is API Service Grade Certi-
rear of the engine on the 4.7L engines. (Fig. 6).
fied. MOPARt provides engine oils that conform to
this service grade.

SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 or 10W-30 in the 4.7L
engines. These are specified with a dual SAE viscos-
ity grade which indicates the cold-to-hot temperature
viscosity range. Select an engine oil that is best
suited to your particular temperature range and vari-
ation (Fig. 4).

Fig. 6 Engine Oil Dipstick 4.7L Engine

1 – TRANSMISSION DIPSTICK
2 – ENGINE OIL DIPSTICK
Fig. 4 Temperature/Engine Oil Viscosity—4.7L
3 – ENGINE OIL FILL CAP
Engine

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 DN 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. (3) Rotate the oil filter counterclockwise (Fig. 7) to
remove it from the cylinder block oil filter boss.
Inspect engine oil level approximately every 800
kilometers (500 miles). Unless the engine has exhib-
ited loss of oil pressure, run the engine for about five
minutes before checking oil level. Checking engine oil
level on a cold engine is not accurate.
To ensure proper lubrication of an engine, the
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.
(1) Position vehicle on level surface.
(2) With engine OFF, allow approximately ten min-
utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Install dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the ADD mark on
dipstick.

ENGINE OIL CHANGE

Change engine oil at mileage and time intervals Fig. 7 Oil Filter—4.7L Engine
described in Maintenance Schedules. 1 – ENGINE OIL FILTER
Run engine until achieving normal operating tem-
perature. (4) When filter separates from cylinder block oil
(1) Position the vehicle on a level surface and turn filter boss, tip gasket end upward to minimize oil
engine off. spill. Remove filter from vehicle.
(2) Hoist and support vehicle on safety stands. (5) With a wiping cloth, clean the gasket sealing
(3) Remove oil fill cap. surface of oil and grime.
(4) Place a suitable drain pan under crankcase
drain. OIL FILTER INSTALLATION
(5) Remove drain plug from crankcase and allow (1) Lightly lubricate oil filter gasket with engine
oil to drain into pan. Inspect drain plug threads for oil.
stretching or other damage. Replace drain plug if (2) Thread filter onto adapter nipple. When gasket
damaged. makes contact with sealing surface, (Fig. 8) hand
(6) Install drain plug in crankcase. tighten filter one full turn, do not over tighten.
(7) Lower vehicle and fill crankcase with specified (3) Add oil, verify crankcase oil level and start
type and amount of engine oil described in this sec- engine. Inspect for oil leaks.
tion.
(8) Install oil fill cap. USED ENGINE OIL DISPOSAL
(9) Start engine and inspect for leaks. Care should be exercised when disposing used
(10) Stop engine and inspect oil level. engine oil after it has been drained from a vehicle
engine. Refer to the WARNING at beginning of this
ENGINE OIL FILTER CHANGE section.

FILTER SPECIFICATION REPAIR DAMAGED OR WORN THREADS

All engines are equipped with a high quality full-
flow, disposable type oil filter. DaimlerChrysler Cor- CAUTION: Be sure that the tapped holes maintain
poration recommends a Mopar or equivalent oil filter the original center line.
be used.

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 9 - 18 4.7L ENGINE DN
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. Essen- Fig. 9 Cylinder Bore Crosshatch Pattern
tially, this repair consists of: 1 – CROSSHATCH PATTERN
• Drilling out worn or damaged threads. 2 – INTERSECT ANGLE
• Tapping the hole with a special Heli-Coil Tap, or
equivalent.
(4) A controlled hone motor speed between 200 and
• Installing an insert into the tapped hole to bring
300 RPM is necessary to obtain the proper cross-
the hole back to its original thread size.
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50° to 60°
CYLINDER BORE—HONING angle. Faster up and down strokes increase the cross-
Before honing, stuff plenty of clean shop towels
hatch angle.
under the bores and over the crankshaft to keep
(5) After honing, it is necessary that the block be
abrasive materials from entering the crankshaft
cleaned to remove all traces of abrasive. Use a brush
area.
to wash parts with a solution of hot water and deter-
(1) Used carefully, the Cylinder Bore Sizing Hone
gent. Dry parts thoroughly. Use a clean, white, lint-
C-823, equipped with 220 grit stones, is the best tool
free cloth to check that the bore is clean. Oil the
for this job. In addition to deglazing, it will reduce
bores after cleaning to prevent rusting.
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
HYDROSTATIC LOCK
When an engine is suspected of hydrostatic lock
its.
(regardless of what caused the problem), follow the
CAUTION: DO NOT use rigid type hones to remove steps below.
cylinder wall glaze. (1) Perform the Fuel Pressure Release Procedure
(refer to Group 14, Fuel System).
(2) Deglazing of the cylinder walls may be done if (2) Disconnect the battery negative cable.
the cylinder bore is straight and round. Use a cylin- (3) Inspect air cleaner, induction system and
der surfacing hone, Honing Tool C-3501, equipped intake manifold to ensure system is dry and clear of
with 280 grit stones (C-3501-3810). about 20-60 foreign material.
strokes, depending on the bore condition, will be suf- (4) Place a shop towel around the spark plugs to
ficient to provide a satisfactory surface. Using honing catch any fluid that may possibly be under pressure
oil C-3501-3880, or a light honing oil, available from in the cylinder head. Remove the plugs from the
major oil distributors. engine.

CAUTION: DO NOT use engine or transmission oil, CAUTION: DO NOT use the starter motor to rotate
mineral spirits, or kerosene. the crankshaft. Severe damage could occur.

(3) Honing should be done by moving the hone up (5) With all spark plugs removed, rotate the crank-
and down fast enough to get a crosshatch pattern. shaft using a breaker bar and socket.

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 DN 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. This will prevent damage on restart.
(10) Install new spark plugs.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N·m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil.
(15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.

VALVE SERVICE
REFACING
Fig. 10 Valve Assembly Configuration
1 – VALVE LOCKS (3–BEAD)
NOTE: Valve seats that are worn or burned can be
2 – RETAINER
reworked, provided that correct angle and seat
3 – VALVE STEM OIL SEAL
width are maintained. Otherwise the cylinder head 4 – INTAKE VALVE
must be replaced. 5 – EXHAUST VALVE
6 – VALVE SPRING

NOTE: When refacing valves and valve seats, it is

important that the correct size valve guide pilot be ENGINE TIMING—VERIFICATION
used for reseating stones. A true and complete sur-
face must be obtained. CAUTION: The 4.7L is a non free-wheeling design
engine. Therefore, correct engine timing is critical.
(1) Using a suitable dial indicator measure the
center of the valve seat Total run out must not
exceed 0.051 mm (0.002 in). NOTE: Components referred to as left hand or right
(2) Apply a small amount of Prussian blue to the hand are as viewed from the drivers position inside
valve seat, insert the valve into the cylinder head, the vehicle.
while applying light pressure on the valve rotate the
valve. Remove the valve and examine the valve face.
NOTE: The blue link plates on the chains and the
If the blue is transferred below the top edge of the
dots on the camshaft drive sprockets may not line
valve face, lower the valve seat using a 15 degree
up during the timing verification procedure. The
stone. If the blue is transferred to the bottom edge of
blue link plates are lined up with the sprocket dots
the valve face, raise the valve seat using a 65 degree
only when re-timing the complete timing drive.
stone.
Once the timing drive is rotated blue link-to-dot
(3) When the seat is properly positioned the width
alignment is no longer valid.
of the intake seat must be 1.75 – 2.36 mm (0.0689 –
0.0928 in.) and the exhaust seat must be 1.71 – 2.32 Engine base timing can be verified by the following
mm (0.0673 – 0.0911 in.). procedure:
(4) Check the valve spring installed height after (1) Remove the cylinder head covers. Refer to the
refacing the valve and seat. The installed height for procedure in this section.
both intake and exhaust valve springs must not (2) Using a mirror, locate the TDC arrow on the
exceed 41.44 mm (1.6315 in.). front cover (Fig. 11). Rotate the crankshaft until the
(5) The valve seat and valve face must maintain a mark on the crankshaft damper is aligned with the
face angle of 44.5 – 45 degrees angle. TDC arrow on the front cover. The engine is now at
TDC.

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 9 - 20 4.7L ENGINE DN
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. 13).
(2) Remove the camshaft drive gear retaining bolt.
(3) Carefully remove the camshaft drive gear from
the camshaft.
(4) Re-index the camshaft drive gear in the chain
until the V8 mark is at the same position as the V8
mark on the opposite camshaft drive gear.

NOTE: When gripping the camshaft, place the pli-

ers on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.

(5) Using a suitable pair of adjustable pliers,

rotate the camshaft until the alignment dowel on the
camshaft is aligned with the slot in the camshaft
Fig. 11 Engine Top Dead Center (TDC) Indicator
drive gear (Fig. 14).
Mark
1 – TIMING CHAIN COVER CAUTION: Remove excess oil from camshaft
2 – CRANKSHAFT TIMING MARKS
sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torqueing of bolt
(3) Note the location of the V8 mark stamped into resulting in bolt failure.
the camshaft drive gears (Fig. 12). If the V8 mark on
each camshaft drive gear is at the twelve o’clock posi- (6) Position the camshaft drive gear onto the cam-
tion, the engine is at TDC on the exhaust stroke. If shaft, remove oil from bolt then install the retaining
the V8 mark on each gear is at the six o’clock posi- bolt. Using Special Tools, Spanner Wrench 6958 with
tion, the engine is at TDC on the compression stroke. Adapter Pins 8346 and a suitable torque wrench,
(4) If both of the camshaft drive gears are off in Tighten retaining bolt to 122N·m (90 ft. Lbs.) (Fig.
the same or opposite directions, the primary chain or 15) (Fig. 16).
both secondary chains are at fault. Refer to Timing (7) Remove special tool 8350.
Chain and Sprockets procedure in this section. (8) Rotate the crankshaft two full revolutions, then
(5) If only one of the camshaft drive gears is off reverify that the camshaft drive gear V8 marks are
and the other is correct, the problem is confined to in fact aligned.
one secondary chain. Refer to Single camshaft tim- (9) Install the cylinder head covers. Refer to Cylin-
ing, in this procedure. der Head Cover in this section.
(6) If both camshaft drive gear V8 marks are at
the twelve o’clock or the six o’ clock position the
engine base timing is correct. Reinstall the cylinder
head covers.

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 DN 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 – RIGHT CYLINDER HEAD 4 – SPECIAL TOOL 8350 WEDGE

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 9 - 22 4.7L ENGINE DN
SERVICE PROCEDURES (Continued)

Fig. 14 Camshaft Dowel To Sprocket Alignment

1 – ADJUSTABLE PLIERS
2 – CAMSHAFT DOWEL

TIMING CHAIN—MEASURING WEAR

NOTE: This procedure must be performed with the Fig. 15 Camshaft Sprocket Installation—Left
timing chain cover removed. Cylinder Head
1 – TORQUE WRENCH
(1) Remove the timing chain cover. Refer to Timing 2 – CAMSHAFT SPROCKET
3 – LEFT CYLINDER HEAD
Chain Cover in this section for procedure.
4 – SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
(2) To determine if the secondary timing chains
are worn, rotate the engine clockwise until maximum
tensioner piston extension is obtained. Measure the an additional bore reading 90 degrees to that at point
distance between the secondary timing chain ten- B (Fig. 19).
sioner housing and the step ledge on the piston (Fig. (3) The coated pistons will be serviced with the
17). The measurement at point (A) must be less than piston pin and connecting rod pre-assembled. Tin
15mm (.5906 inches). coated pistons should not be used as replacements for
(3) If the measurement exceeds the specification coated pistons.
the secondary timing chains are worn and require (4) The coating material is applied to the piston
replacement. Refer to Timing Chain and Sprockets in after the final piston machining process. Measuring
this section for procedure. the outside diameter of a coated piston will not pro-
vide accurate results (Fig. 18). Therefore measuring
PISTONS—FITTING the inside diameter of the cylinder bore with a dial
BORE GAGE METHOD Bore Gauge is MANDATORY. To correctly select the
(1) To correctly select the proper size piston, a cyl- proper size piston, a cylinder bore gauge capable of
inder bore gauge, capable of reading in 0.003 mm reading in 0.003 mm (.0001 in.) increments is
(.0001 in.) INCREMENTS is required. If a bore required.
gauge is not available, do not use an inside microme- (5) Piston installation into the cylinder bore
ter. requires slightly more pressure than that required
(2) Measure the inside diameter of the cylinder for non-coated pistons. The bonded coating on the
bore at a point 49.5 mm (1-15/16 inches) below top of piston will give the appearance of a line-to-line fit
bore. Start perpendicular (across or at 90 degrees) to with the cylinder bore.
the axis of the crankshaft at point A and then take

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 DN 4.7L ENGINE 9 - 23
SERVICE PROCEDURES (Continued)

Fig. 18 Moly Coated Piston

Fig. 16 Camshaft Sprocket Installation—Right 1 – MOLY COATED
Cylinder Head 2 – MOLY COATED
1 – TORQUE WRENCH
2 – SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 – LEFT CAMSHAFT SPROCKET
4 – RIGHT CAMSHAFT SPROCKET

Fig. 19 Bore Gauge—Typical

1 – FRONT
2 – BORE GAUGE
3 – CYLINDER BORE
4 – 49.5 MM
Fig. 17 Measuring Secondary Timing Chains For (1–15/16 in)
Stretch
1 – SECONDARY TENSIONER ARM
2 – SECONDARY CHAIN TENSIONER PISTON

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 9 - 24 4.7L ENGINE DN
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.
NOTE: The ring gap measurement must be made
with the ring positioned at least 12mm (0.50 inch.)
from bottom of cylinder bore.
(3) Using a piston, to ensure that the ring is
squared in the cylinder bore, slide the ring downward
into the cylinder.
(4) Using a feeler gauge check the ring end gap
(Fig. 20). Replace any rings not within specification.

Fig. 21 Measuring Piston Ring Side Clearance

1 – FEELER GAUGE

PISTON RING SPECIFICATION CHART

Ring Position Groove Maximum

Clearance Clearance
Upper Ring .051-.094mm 0.11mm
Fig. 20 Ring End Gap Measurement—Typical
(0.0020-.0037 (0.004 in.)
1 – FEELER GAUGE in.)

PISTON RING SIDE CLEARANCE Intermediate 0.04-0.08mm 0.10mm

Ring
NOTE: Make sure the piston ring grooves are clean
(0.0016-0.0031 (0.004 in.)
and free of nicks and burrs. in.)
(5) Measure the ring side clearance as shown (Fig.
Oil Control Ring .019-.229mm .25mm
21) make sure the feeler gauge fits snugly between
the ring land and the ring. Replace any ring not (Steel Rails) (.0007-.0090 in.) (0.010 in.)
within specification. Ring Position Ring Gap Wear Limit
(6) Rotate the ring around the piston, the ring
must rotate in the groove with out binding. Upper Ring 0.20-0.36mm 0.40mm
(0.008-0.014 in.) (0.0016in.)
EARLY BUILD
Intermediate 0.37-0.63mm 0.71mm
(7) The No. 1 and No. 2 piston rings have a differ- Ring
ent cross section. Ensure No. 2 ring is installed with
manufacturers I.D. mark (Dot) facing up, towards top (0.014-0.025 in.) (0.028in.)
of the piston. Oil Control Ring 0.025-0.76mm 1.52mm

LATE BUILD (Steel Rail) (0.010- 0.030 (0.060in.)

in.)
The No. 1 and No. 2 piston rings have a different
cross section. Ensure No. 2 ring is installed with
manufacturers I.D. mark (Dot) facing up, towards top installing piston rings on late build engines that the
of the piston. On late build engines the piston top correct No. 1 piston ring be installed, failure to use
ring groove and crown are not anodized therefore, the correct piston ring can cause severe damage to
the No. 1 piston ring is coated with an anti-friction the piston and/or cylinder block.
coating. Care must be used to ensure that when

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 DN 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.

(9) Install upper side rail (Fig. 22) 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.
(10) Install No. 2 intermediate piston ring using a
piston ring installer (Fig. 23).
(11) Install No. 1 upper piston ring using a piston Fig. 23 Upper and Intermediate Rings—Installation
ring installer (Fig. 23).
(12) Position piston ring end gaps as shown in
(Fig. 24). 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.

Fig. 24 Piston Ring End Gap Position

1 – SIDE RAIL UPPER
2 – NO. 1 RING GAP
3 – PISTON PIN
4 – SIDE RAIL LOWER
5 – NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 22 Side Rail—Installation
1 – SIDE RAIL END
alignment. Replace misaligned, bent or twisted con-
necting rods.
CONNECTING ROD BEARINGS—FITTING (1) Wipe the oil from the connecting rod journal.
Inspect the connecting rod bearings for scoring and (2) Lubricate the upper bearing insert and install
bent alignment tabs (Fig. 25) (Fig. 26). Check the in connecting rod.
bearings for normal wear patterns, scoring, grooving, (3) Use piston ring compressor and Guide Pins
fatigue and pitting (Fig. 27). Replace any bearing Special Tool 8507 (Fig. 28) to install the rod and pis-
that shows abnormal wear. ton assemblies. The oil slinger slots in the rods must
Inspect the connecting rod journals for signs of face front of the engine. The “F”’s near the piston
scoring, nicks and burrs. wrist pin bore should point to the front of the engine.
Misaligned or bent connecting rods can cause (4) Install the lower bearing insert in the bearing
abnormal wear on pistons, piston rings, cylinder cap. The lower insert must be dry. Place strip of Plas-
walls, connecting rod bearings and crankshaft con- tigage across full width of the lower insert at the cen-
necting rod journals. If wear patterns or damage to ter of bearing cap. Plastigage must not crumble in
any of these components indicate the probability of a use. If brittle, obtain fresh stock.
misaligned connecting rod, inspect it for correct rod

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 9 - 26 4.7L ENGINE DN
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 – LOWER BEARING HALF

Fig. 28 Piston and Connecting Rod—Installation

1 – “F” TOWARD FRONT OF ENGINE
2 – OIL SLINGER SLOT
3 – RING COMPRESSOR
4 – SPECIAL TOOL 8507

(5) Install bearing cap and connecting rod on the

journal and tighten bolts to 27 N·m (20 ft. lbs.) plus a
90° turn. DO NOT rotate crankshaft. Plastigage will
smear, resulting in inaccurate indication.
(6) Remove the bearing cap and determine amount
of bearing-to-journal clearance by measuring the
width of compressed Plastigage (Fig. 29). Refer to
Fig. 26 Locking Tab Inspection Engine Specifications for the proper clearance. Plas-
1 – ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS tigage should indicate the same clearance
NOT FULLY SEATED OR BEING BENT
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(7) If the correct clearance is indicated, replace-
ment of the bearing inserts is not necessary. Remove
the Plastigage from crankshaft journal and bearing
insert. Proceed with installation.
(8) If bearing-to-journal clearance exceeds the
specification, determin which services bearing set to
Fig. 27 Scoring Caused by Insufficient Lubrication use the bearing sizes are as follows:
or by Damaged Crankshaft Pin Journal

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 DN 4.7L ENGINE 9 - 27
SERVICE PROCEDURES (Continued)

Fig. 29 Measuring Bearing Clearance with Fig. 30 Checking Connecting Rod Side Clearance—
Plastigage Typical
1 – PLASTIGAGE SCALE
2 – COMPRESSED PLASTIGAGE

Bearing SIZE USED WITH

Mark
JOURNAL SIZE

.025 US .025 mm 50.983-50.967 mm

(.001 in.) (2.0073-2.0066 in.)

Std. STANDARD 50.992-51.008 mm

(2.0076-2.0082 in.)

.250 US .250 mm 50.758-50.742 mm

(.010 in.) (1.9984-1.9978 in.)
Fig. 31 Main Bearing Wear Patterns
1 – UPPER INSERT
(9) Repeat the Plastigage measurement to verify
2 – NO WEAR IN THIS AREA
your bearing selection prior to final assembly. 3 – LOW AREA IN BEARING LINING
(10) Once you have selected the proper insert, 4 – LOWER INSERT
install the insert and cap. Tighten the connecting rod
bolts to 27 N·m (20 ft. lbs.) plus a 90° turn.
Slide snug-fitting feeler gauge between the con- Inspect the back of the inserts for fractures, scrap-
necting rod and crankshaft journal flange (Fig. 30). ings or irregular wear patterns.
Refer to Engine Specifications for the proper clear- Inspect the upper insert locking tabs for damage.
ance. Replace the connecting rod if the side clearance Replace all damaged or worn bearing inserts.
is not within specification.
MAIN BEARING JOURNAL DIAMETER
CRANKSHAFT MAIN BEARINGS (CRANKSHAFT REMOVED)
Remove the crankshaft from the cylinder block.
INSPECTION Refer to Crankshaft in this section for procedure.
Wipe the inserts clean and inspect for abnormal Clean the oil off the main bearing journal.
wear patterns and for metal or other foreign material Determine the maximum diameter of the journal
imbedded in the lining. Normal main bearing insert with a micrometer. Measure at two locations 90°
wear patterns are illustrated (Fig. 31). apart at each end of the journal.
The maximum allowable taper is 0.008mm (0.0004
NOTE: If any of the crankshaft journals are scored, inch.) and maximum out of round is 0.005mm (0.002
remove the engine for crankshaft repair. inch). Compare the measured diameter with the jour-

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 9 - 28 4.7L ENGINE DN
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. The chart below identifies the three service
grades available.

GRADE SIZE mm FOR USE WITH

(in.)
MARKING JOURNAL SIZE

A .008 mm U/S 63.488-63.496 mm Fig. 32 Engine Insulator Mount 4x2 Vehicle—Left

(.0004 in.) (2.4996-2.4999 in.) Side
U/S 1 – ENGINE INSULATOR MOUNT-LEFT SIDE
2 – MOUNTING BOLT
B STANDARD 63.496-63.504 mm
(2.4996-2.4999 in.)

C .008 mm O/S 63.504-63.512 mm

(.0004 in.) (2.5002-2.5005 in.)
O/S

REMOVAL AND INSTALLATION

ENGINE MOUNTS—LEFT AND RIGHT
REMOVAL
(1) Disconnect the negative cable from the battery.

CAUTION: Remove the fan blade, fan clutch and

fan shroud before raising engine. Failure to do so
may cause damage to the fan blade, fan clutch and Fig. 33 Engine Insulator Mount 4x2 Vehicle—Right
fan shroud. Side
1 – ENGINE INSULATOR MOUNT-RIGHT SIDE
(2) Remove the fan blade, fan clutch and fan 2 – MOUNTING BOLT
shroud. Refer to Group 7. for procedure.
(3) Remove the engine oil filter.
(4) Support the engine with a suitable jack and a INSTALLATION
block of wood across the full width of the engine oil (1) Position the insulator mount and install the
pan. insulator mount through bolt.
(5) Remove the four (4) cylinder block-to-insulator (2) Lower the engine until the four cylinder block-
mount bolts and the nut from the engine insulator to-insulator mount bolts can be installed.
mount through bolt (4x2 Vehicles only) (Fig. 32) (Fig. (3) Remove the jack and block of wood.
33). (4) Torque the cylinder block-to-insulator mount
(6) Remove the three (3) cylinder block-to-insulator bolts to 61N·m ( 45 ft. lbs.).
mount bolts and loosen the nut from the engine insu- (5) Install and torque the through bolt retaining
lator mount through bolt (4x4 Vehicles only) (Fig. 34) nut to 61N·m (45 ft. lbs.).
(Fig. 35). (6) Install the fan blade, fan clutch and fan
(7) Using the jack, raise the engine high enough to shroud.
remove the engine insulator mount through bolt and
the insulator mount.

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 DN 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. 36) (Fig. 37).
(6) Raise the transmission and remove the bolts
retaining the mount to the crossmember (4x4 auto-
matic transmission only) (Fig. 38).
(7) Remove the two nuts retaining the isolator to
the crossmember (Manual transmission and 4x2
automatic transmission only) (Fig. 36) (Fig. 37).
(8) Remove the bolts (two bolts manual transmis-
sion)(three bolts 4x2 automatic transmission) retain-
ing the insulator bracket to the transmission.

Fig. 34 Engine Insulator Mount 4x4 Vehicle—Left

Side
1 – ENGINE INSULATOR MOUNT-LEFT SIDE
2 – MOUNTING BOLT

Fig. 36 Engine Rear Mount—4X2 Automatic

Transmission
1 – ENGINE REAR MOUNT
2 – BOLT
3 – NUT
4 – THROUGH BOLT NUT
5 – TRANSMISSION

INSTALLATION
Fig. 35 Engine Insulator Mount 4x4 Vehicle—Right (1) Follow the removal procedure in the reverse
Side order.
1 – ENGINE INSULATOR MOUNT-RIGHT SIDE (2) Tighten the through bolt retaining nut to 102
2 – MOUNTING BOLT N·m (75 ft. lbs.).
(3) Tighten the isolator bracket to transmission
ENGINE MOUNT—REAR retaining bolts (Manual transmission and 4x2 auto-
matic transmission only) to 41 N·m (30 ft. lbs.).
REMOVAL (4) Tighten the mount bracket to transmission
retaining bolts (4x4 automatic transmission only) to
(1) Raise vehicle on hoist.
68 N·m (50 ft. lbs.).
(2) Using a suitable jack, support transmission.
(5) Tighten the isolator mount to crossmember
(3) Remove the nut from the insulator mount
retaining nuts (Manual transmission and 4x2 auto-
through bolt (Manual transmission and 4x2 auto-
matic transmission only) to 28 N·m (250 in. lbs.).
matic transmission only) (Fig. 36) (Fig. 37).

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 9 - 30 4.7L ENGINE DN
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.
(4) Remove the eight bolts retaining structural
cover (Fig. 39).
(5) Pivot the exhaust pipe downward and remove
the structural cover.

INSTALLATION
CAUTION: The structural cover must be installed
as described in the following steps. Failure to do so
Fig. 37 Engine Rear Mount—4X2 and 4X4 Manual will cause severe damage to the cover.
Transmission
1 – THROUGH BOLT (1) Position the structural cover in the vehicle.
2 – BOLT (2) Install all four bolts retaining the cover-to-en-
3 – INSULATOR SUPPORT gine. DO NOT tighten the bolts at this time.
4 – NUT (3) Install the four cover-to-transmission bolts. Do
5 – NUT AND WASHER NOT tighten at this time.
6 – INSULATOR BRACKET TO TRANSMISSION
CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.

(4) Starting with the two rear cover-to-engine

bolts, tighten bolts (1) (Fig. 39) to 54 N·m (40 ft. lbs.),
then tighten bolts (2) (Fig. 39) and (3) to 54 N·m ( 40
ft. lbs.) in the sequence shown.

Fig. 38 Engine Rear Mount—4X4 Automatic

Transmission
1 – TRANSMISSION
2 – ENGINE REAR MOUNT
3 – BOLT
Fig. 39 Structural Cover
(6) Tighten the mount bracket to crossmember (5) Install the exhaust pipe on left hand exhaust
retaining bolts (4x4 automatic transmission only) to manifold.
28 N·m (250 in. lbs.). (6) Tighten exhaust manifold-to-exhaust pipe
retaining bolts to 20–26 N·m (15–20 ft. lbs.).

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 DN 4.7L ENGINE 9 - 31
REMOVAL AND INSTALLATION (Continued)

SEQUENCE ITEM TORQUE

1 BOLT 54 N·m

(Qty 4) (40 ft. lbs.)

2 BOLT 54 N·m

(Qty 2) (40 ft. lbs.)

3 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.

(1) Disconnect the battery negative and positive

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

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 9 - 32 4.7L ENGINE DN
REMOVAL AND INSTALLATION (Continued)

Fig. 41 Engine Mount Through Bolt and Nut

Removal / Installation—4X4 Vehicles
1 – ENGINE MOUNT BRACKET (2)
2 – THROUGH BOLT (2) Fig. 42 Axle Isolator Bracket Removal /
3 – LOCKNUT AND WASHER (2) Installation—4X4 Vehicles With Automatic
4 – ENGINE ISOLATOR TO ENGINE MOUNT BRACKET STUD (2) Transmission
5 – LOCKNUT (2) 1 – TRANSMISSION
2 – AXLE ISOLATOR BRACKET
• Throttle Position (TPS) Switch 3 – FRONT AXLE 4X4 VEHICLES
4 – BOLTS
• Idle Air Control (IAC) Motor
5 – ENGINE
• Engine Oil Pressure Switch
• Engine Coolant Temperature (ECT) Sensor
• Manifold absolute pressure (MAP) Sensor • Secure the lifting fixture to the three studs
• Camshaft Position (CMP) Sensor using three 7/16 – 14 N/C locknuts.
• Coil Over Plugs • Make sure the lifting loop in the lifting fixture is
(31) Disconnect the vacuum lines at the throttle in the last hole (closest to the throttle body) to min-
body and intake manifold. imize the angle of engine during removal.
(32) Release fuel rail pressure then disconnect the (36) Disconnect body ground strap at the right side
fuel supply quick connect fitting at the fuel rail. cowl (Fig. 48).
Refer toFUEL SYSTEM for procedure. (37) Disconnect body ground strap at the left side
(33) Remove power steering pump and position out cowl (Fig. 49).
of the way.
(34) Install Special Tools 8400 Lifting Studs, into NOTE: It will be necessary to support the transmis-
the cylinder heads. sion in order to remove the engine.
(35) Install Engine Lifting Fixture Special Tool
8347 (Fig. 47) following these steps. (38) Position a suitable jack under the transmis-
• Holding the lifting fixture at a slight angle, slide sion.
the large bore in the front plate over the hex portion (39) Remove engine from the vehicle.
of the lifting stud.
• Position the two remaining fixture arms onto INSTALLATION
the two Special Tools 8400 Lifting Studs, in the cyl- (1) Position engine in the vehicle.
inder heads. Position both the left and right side engine mount
• Pull foward and upward on the lifting fixture so brackets and install the through bolts and nuts.
that the lifting stud rest in the slotted area below the Tighten nuts to 4X2 vehicles 95 N·m (70 ft. lbs.).
large bore. 4X4 vehicles 102 N·m (75 ft. lbs.).

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 DN 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 – CAMSHAFT POSITION SENSOR
4 – RIGHT SIDE CYLINDER BLOCK (8) Install power steering pump.
(9) Connect fuel supply line quick connect fitting.
(10) Connect the vacuum lines at the throttle body
and intake manifold.
(11) Connect engine harness at the following
points (Fig. 46) :
• Intake Air Temperature (IAT) Sensor
• Idle Air Control (IAC) Motor
• Fuel Injectors
• Throttle Position (TPS) Switch
• Engine Oil Pressure Switch
• Engine Coolant Temperature (ECT) Sensor
• Manifold Absolute Pressure (MAP) Sensor
• Camshaft Position (CMP) Sensor
• Coil Over Plugs
(12) Position and install heater hoses and tubes
Fig. 44 Crankcase Breather Connection Points
onto intake manifold.
1 – CRANKCASE BREATHERS
(13) Install the heater hoses onto the heater core
and the engine front cover.
(2) 4X4 vehicles Install locknuts onto the engine (14) Install generator.
mount brackets. Tighten locknuts to 41 N·m (30 ft. (15) Install A/C condenser, radiator and transmis-
lbs.). sion oil cooler as an assembly.
(3) Remove jack from under the transmission. (16) Connect radiator upper and lower hoses.
(4) Remove Engine Lifting Fixture Special Tool (17) Connect the transmission oil cooler lines to
8347 (Fig. 47). the radiator.
(5) Remove Special Tools 8400 Lifting Studs. (18) Install accessory drive belt, fan assembly and
(6) Position generator wiring behind the oil dip- shroud.
stick tube, then install the oil dipstick tube upper (19) Install A/C compressor. Tighten the A/C com-
mounting bolt. pressor and generator M10 mounting bolts 40–68N·M
(7) Connect both left and right side body ground (30–50 ft. lbs.) and the M8 bolts 22–34 N·m (200–300
straps. in. lbs.).

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 9 - 34 4.7L ENGINE DN
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 – MOUNTING SCREWS 2 – ADJUSTABLE HOOK
3 – SPECIAL TOOL 8347 ENGINE LIFT FIXTURE
4 – ATTACHING LOCATIONS
(20) Install both breathers. Connect tube to both
crankcase breathers (Fig. 44).
(21) Connect throttle and speed control cables. (29) Install structural cover. Refer to Structural
(22) Install throttle body resonator assembly and Cover in this section.
air inlet hose. Tighten clamps 4 N·m (35 in. lbs.). (30) Install exhaust crossover pipe.
(23) Raise vehicle. (31) Install engine block heater power cable, If
(24) Install transmission to engine mounting bolts. equipped.
Tighten the bolts to 41 N·m (30 ft. lbs.). (32) 4X4 vehicles Connect axle vent tube to left
(25) Install torque converter bolts (Automatic side engine mount.
Transmission Only). (33) Lower vehicle.
(26) Connect crankshaft position sensor (Fig. 43). (34) Check and fill engine oil.
(27) 4X4 vehicles Position and install the axle (35) Recharge the A/C system.
isolator bracket onto the axle, transmission and (36) Refill the engine cooling system. Refer to
engine block. Tighten bolts to specification. Refer to COOLING SYSTEM.
Specifications in this section. (37) Install the battery tray and battery.
(28) Install starter. (38) Connect the battery positive and negative
cables.
CAUTION: The structural cover requires a specific (39) Start the engine and check for leaks.
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.

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 DN 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.
• Manifold Absolute Pressure (MAP) Sensor
• Intake Air Temperature (IAT) Sensor
• Throttle Position (TPS) Sensor
• Coolant Temperature (CTS) Sensor
• Idle 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.
Fig. 48 Body Ground Strap—Right Side Removal / (9) Disconnect and remove ignition coil towers.
Installation (10) Remove top oil dipstick tube retaining bolt
1 – NUT and ground strap.
2 – A/C ACCUMULATOR (11) Bleed fuel system. Refer to FUEL SYSTEM.
3 – GROUND STRAP
(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.
Fig. 49 Body Ground Strap—Left Side Removal / (7) Connect throttle cable and speed control cable
Installation to throttle body.
1 – NUT (8) Install fuel rail.
2 – GROUND STRAP (9) Install ignition coil towers.
3 – BRAKE BOOSTER

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 9 - 36 4.7L ENGINE DN
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
• Ignition coil towers
• Fuel 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
Fig. 50 Heater Hoses and Tubes Removal /
Installation RIGHT EXHAUST MANIFOLD
1 – HEATER HOSES AND TUBES
2 – ROUTING/RETAINING CLIPS 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
Fig. 51 Intake Manifold Tightening Sequence starter aside.
(14) Remove lower exhaust manifold attaching fas-
(10) Position and install heater hoses and tubes
teners.
onto intake manifold.
(15) Remove exhaust manifold and gasket (Fig.
(11) Install the heater hoses to the heater core and
52). Manifold is removed from below the engine com-
engine front cover.
partment.

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 DN 4.7L ENGINE 9 - 37
REMOVAL AND INSTALLATION (Continued)

Fig. 52 Exhaust Manifold—Right

ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE

1 Stud (Qty 2) 4 Nut (Qty 2) 8 N·m
(72 in. lbs.), then
25 N·m loosen 45
2 Bolt (Qty 4) 5 Nut (Qty 2)
(18 ft. lbs.) degrees
3 Stud (Qty 2)

INSTALLATION CAUTION: Over tightening heat shield fasteners,

(1) Install exhaust manifold and gasket from below may cause shield to distort and/or crack.
engine compartment.
(2) Install lower exhaust manifold fasteners. DO (4) Install exhaust manifold heat shield. Tighten
NOT tighten until all fasteners are in place. fasteners to 8 N·m (72 in. lbs.), then loosen 45
(3) Lower vehicle and install upper exhaust mani- degrees.
fold fasteners. Tighten all manifold bolts starting at (5) Install starter and fasteners.
center and working outward to 25 N·m (18 ft. lbs.). (6) Connect exhaust pipe to manifold.
(7) Connect heater hoses at engine.
(8) Install fastener attaching A/C accumulator.

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 9 - 38 4.7L ENGINE DN
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. bolts.
(12) Install battery and connect cables. (7) Remove cylinder head cover and gasket.
(13) Fill cooling system.
NOTE: The gasket may be used again, provided no
LEFT EXHAUST MANIFOLD cuts, tears, or deformation has occurred.

REMOVAL
(1) Disconnect negative cable for battery. INSTALLATION
(2) Hoist vehicle.
CAUTION: Do not use harsh cleaners to clean the
(3) Disconnect exhaust pipe at manifold.
cylinder head covers. Severe damage to covers
(4) Lower vehicle.
may occur.
(5) Remove the front two exhaust heat shield
retaining fasteners. Raise vehicle and remove the
fasteners at rear of heat shield. CAUTION: DO NOT allow other components includ-
(6) Remove heat shield (Fig. 53). ing the wire harness to rest on or against the cylin-
(7) Lower vehicle and remove the upper exhaust der head cover. Prolonged contact with other
manifold retaining bolts (Fig. 53). objects may wear a hole in the engine cylinder head
(8) Raise vehicle and remove the lower exhaust cover.
manifold retaining bolts (Fig. 53).
(9) Remove exhaust manifold and gasket (Fig. 53). (1) Clean cylinder head cover and both sealing sur-
Manifold is removed from below the engine compart- faces. Inspect and replace gasket as necessary.
ment. (2) Install cylinder head cover and hand start all
fasteners. Verify that all studs are in the correct loca-
INSTALLATION tion shown in (Fig. 54).
(1) Install exhaust manifold and gasket from below (3) Tighten cylinder head cover bolts and double
engine compartment. ended studs to 12 N·m (105 in. lbs.).
(2) Install lower exhaust manifold fasteners (Fig. (4) Install left side breather and connect breather
53). DO NOT tighten until all fasteners are in place. tube.
(3) Lower vehicle and install upper exhaust mani- (5) Connect injector electrical connectors and injec-
fold fasteners (Fig. 53). Tighten all manifold bolts tor harness retaining clips.
starting at center and working outward to 25 N·m (6) Install the resonator and air inlet hose.
(18 ft. lbs.). (7) Connect negative cable to battery.

CAUTION: Over tightening heat shield fasteners, REMOVAL

may cause shield to distort and/or crack.
RIGHT SIDE COVER
(4) Install exhaust manifold heat shield (Fig. 53). (1) Disconnect battery negative cable.
Tighten fasteners to 8 N·m (72 in. lbs.), then loosen (2) Remove air cleaner assembly, resonator assem-
45 degrees. bly and air inlet hose.
(5) Connect exhaust pipe to manifold. (3) Drain cooling system, below the level of the
(6) Connect negative cable to battery. heater hoses. Refer to COOLING SYSTEM.
(4) Remove accessory drive belt.
CYLINDER HEAD COVER (5) Remove air conditioning compressor retaining
bolts and move compressor to the left.
REMOVAL (6) Remove heater hoses.
(7) Disconnect injector and ignition coil connectors.
LEFT SIDE COVER
(8) Disconnect and remove positive crankcase ven-
(1) Disconnect negative cable from battery. tilation (PCV) hose.
(2) Remove the resonator assemble and air inlet (9) Remove oil fill tube.
hose. (10) Un-clip injector and ignition coil harness and
(3) Disconnect injector connectors and un-clip the move away from cylinder head cover.
injector harness. (11) Remove right rear breather tube and filter
(4) Route injector harness in front of cylinder head assembly.
cover.

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 DN 4.7L ENGINE 9 - 39
REMOVAL AND INSTALLATION (Continued)

Fig. 53 Exhaust Manifold—Left

ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE

1 Stud (Qty 2) 4 Nut (Qty 2) 8 N·m (72 in.
25 N·m (18 ft. lbs.), then loosen
2 Bolt (Qty 4) 5 Nut (Qty 2) 45 degrees
lbs.)
3 Stud (Qty 2)

(12) Remove cylinder head cover retaining bolts. INSTALLATION

(13) Remove cylinder head cover.
CAUTION: Do not use harsh cleaners to clean the
NOTE: The gasket may be used again, provided no cylinder head covers. Severe damage to covers
cuts, tears, or deformation has occurred. may occur.

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 9 - 40 4.7L ENGINE DN
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.
(10) Install accessory drive belt
(11) Fill Cooling system
(12) Install air cleaner assembly, resonator assem-
bly and air inlet hose.
(13) Connect battery negative cable.

Fig. 54 Cylinder Head Cover—Left ROCKER ARMS

REMOVAL
ITEM DESCRIPTION TORQUE
NOTE: Disconnect the battery negative cable to
1 Cover 12 N·m (105 in. lbs.)
prevent accidental starter engagement.
Fasteners
(1) Remove the cylinder head cover. Refer to Cyl-
CAUTION: DO NOT allow other components includ- inder Head Cover in this section.
ing the wire harness to rest on or against the (2) For rocker arm removal on cylinders 3 and 5
engine cylinder head cover. Prolonged contact with Rotate the crankshaft until cylinder #1 is at TDC
other objects may wear a hole in the cylinder head exhaust stroke.
cover. (3) For rocker arm removal on cylinders 2 and 8
Rotate the crankshaft until cylinder #1 is at TDC
(1) Clean cylinder head cover and both sealing sur- compression stroke.
faces. Inspect and replace gasket as necessary. (4) For rocker arm removal on cylinders 4 and 6
(2) Install cylinder head cover and hand start all Rotate the crankshaft until cylinder #3 is at TDC
fasteners. Verify that all double ended studs are in compression stroke.
the correct location shown in (Fig. 55). (5) For rocker arm removal on cylinders 1 and 7
Rotate the crankshaft until cylinder #2 is at TDC
compression stroke.
(6) Using special tool 8516 press downward on the
valve spring, remove rocker arm (Fig. 56).

INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.

NOTE: Coat the rocker arms with clean engine oil

Fig. 55 Cylinder Head Cover—Right prior to installation.

(1) For rocker arm installation on cylinders 3 and

ITEM DESCRIPTION TORQUE 5 Rotate the crankshaft until cylinder #1 is at TDC
1 Cover Fasteners 12 N·m (105 in. lbs.) exhaust stroke.
(2) For rocker arm installation on cylinders 2 and
8 Rotate the crankshaft until cylinder #1 is at TDC
(3) Tighten cylinder head cover bolts and double compression stroke.
ended studs to 12 N·m (105 in. lbs). (3) For rocker arm installation on cylinders 4 and
(4) Install right rear breather tube and filter 6 Rotate the crankshaft until cylinder #3 is at TDC
assembly. compression stroke.

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 DN 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 – TIMING CHAIN COVER
7 Rotate the crankshaft until cylinder #2 is at TDC 2 – CRANKSHAFT TIMING MARKS
compression stroke.
(5) Using special tool 8516 press downward on the (12) Verify the V8 mark on the camshaft sprocket
valve spring, install rocker arm (Fig. 56). is at the 12 o’clock position (Fig. 59). Rotate the
(6) Install the cylinder head cover. crankshaft one turn if necessary.
(13) Remove the crankshaft damper. Refer to
CYLINDER HEADS Crankshaft Damper in this section.
(14) Remove the timing chain cover. Refer to pro-
CYLINDER HEAD—LEFT cedure in this section.
(15) Lock the secondary timing chains to the idler
REMOVAL sprocket using Special Tool 8515 (Fig. 58).
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist. NOTE: Mark the secondary timing chain prior to
(3) Disconnect the exhaust pipe at the left side removal to aid in installation.
exhaust manifold.
(4) Drain the engine coolant. Refer to COOLING (16) Mark the secondary timing chain, one link on
SYSTEM. each side of the V8 mark on the camshaft drive gear
(5) Lower the vehicle. (Fig. 59).
(6) Remove the intake manifold. Refer to proce- (17) Remove the left side secondary chain ten-
dure in this section. sioner. Refer to Timing Chain and Sprockets in this
(7) Remove the cylinder head cover. Refer to proce- section.
dure in this section. (18) Remove the cylinder head access plug (Fig.
(8) Remove the fan shroud and fan blade assembly. 60).
Refer to COOLING SYSTEM. (19) Remove the left side secondary chain guide.
(9) Remove accessory drive belt. Refer to COOL- Refer to Timing Chain and Sprockets in this section.
ING SYSTEM. (20) Remove the retaining bolt and the camshaft
(10) Remove the power steering pump and set drive gear.
aside.

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 9 - 42 4.7L ENGINE DN
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.

Fig. 58 Using Special Tool 8515 to Hold Chains to

Idler Sprocket.
1 – LOCK ARM
2 – RIGHT CAMSHAFT CHAIN
3 – SECONDARY CHAINS RETAINING PINS (4)
4 – IDLER SPROCKET
Fig. 60 Cylinder Head Access Plugs
5 – LEFT CAMSHAFT CHAIN
1 – RIGHT CYLINDER HEAD ACCESS PLUG
6 – SPECIAL TOOL 8515
2 – LEFT CYLINDER HEAD ACCESS PLUG

CAUTION: Do not allow the engine to rotate. Severe

damage to the valve train can occur.

Fig. 59 Camshaft Sprocket V8 Marks

1 – LEFT CYLINDER HEAD
2 – RIGHT CYLINDER HEAD

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 DN 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.

INSTALLATION

NOTE: The cylinder head bolts are tightened using

a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.

Necking can be checked by holding a straight edge

against the threads. If all the threads do not contact
the scale, the bolt should be replaced (Fig. 61).

Fig. 62 Proper Tool Usage for Surface Preparation

1 – PLASTIC/WOOD SCRAPER

NOTE: The four smaller cylinder head mounting

bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.

(4) Lubricate the cylinder head bolt threads with

clean engine oil and install the ten M11 bolts.
(5) Coat the four M8 cylinder head bolts with
Fig. 61 Checking Cylinder Head Bolts for Stretching Mopart Lock and Seal Adhesive then install the
(Necking) bolts.
1 – STRETCHED BOLT
2 – THREADS ARE NOT STRAIGHT ON LINE NOTE: The cylinder head bolts are tightened using
3 – THREADS ARE STRAIGHT ON LINE an angle torque procedure, however, the bolts are
4 – UNSTRETCHED BOLT not a torque-to-yield design.

(6) Tighten the bolts in sequence (Fig. 63) using

CAUTION: When cleaning cylinder head and cylin- the following steps and torque values:
der block surfaces, DO NOT use a metal scraper • Step 1: Tighten bolts 1–10, 20 N·m (15 ft. lbs.).
because the surfaces could be cut or ground. Use • Step 2: Tighten bolts 1–10, 47 N·m (35 ft. lbs.).
only a wooden or plastic scraper. Tighten bolts 11–14, 25 N·m (18 ft. lbs.).
• Step 3: Tighten bolts 1–10, 90 degrees. Tighten
(1) Clean the cylinder head and cylinder block
bolts 11–14, 30 N·m (22 ft. lbs.).
mating surfaces (Fig. 62).
(7) Position the secondary chain onto the camshaft
(2) Position the new cylinder head gasket on the
drive gear, making sure one marked chain link is on
locating dowels.
either side of the V8 mark on the gear and position
CAUTION: When installing cylinder head, use care the gear onto the camshaft.
not damage the tensioner arm or the guide arm. (8) Install the camshaft drive gear retaining bolt.
(9) Install the left side secondary chain guide.
(3) Position the cylinder head onto the cylinder (10) Install the cylinder head access plug.
block. Make sure the cylinder head seats fully over (11) Re-set and Install the left side secondary
the locating dowels. chain tensioner.
(12) Remove Special Tool 8515.
(13) Install the timing chain cover.

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 9 - 44 4.7L ENGINE DN
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.

(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.
Fig. 63 Cylinder Head Tightening Sequence (18) Remove the cylinder head access plug (Fig.
64).
(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 HEAD—RIGHT
REMOVAL Fig. 64 Cylinder Head Access Plugs
1 – RIGHT CYLINDER HEAD ACCESS PLUG
(1) Disconnect battery negitive cable.
2 – LEFT CYLINDER HEAD ACCESS PLUG
(2) Raise the vehicle on a hoist.
(3) Disconnect the exhaust pipe at the right side
exhaust manifold. (19) Remove the right side secondary chain guide.
(4) Drain the engine coolant. Refer to COOLING Refer to Timing Chain and Sprockets in this section.
SYSTEM. (20) Remove the retaining bolt and the camshaft
(5) Lower the vehicle. drive gear.
(6) Remove the intake manifold. Refer to proce-
dure in this section. CAUTION: Do not allow the engine to rotate. severe
(7) Remove the cylinder head cover. Refer to proce- damage to the valve train can occur.
dure in this section.
(8) Remove the fan shroud. Refer to COOLING
CAUTION: Do not overlook the four smaller bolts at
SYSTEM.
the front of the cylinder head. Do not attempt to
(9) Remove oil fill housing from cylinder head.
remove the cylinder head without removing these
(10) Remove accessory drive belt. Refer to COOL-
four bolts.
ING SYSTEM.
(11) Rotate the crankshaft until the damper timing
mark is aligned with TDC indicator mark (Fig. 57). CAUTION: Do not hold or pry on the camshaft tar-
(12) Verify the V8 mark on the camshaft sprocket get wheel for any reason. A damaged target wheel
is at the 12 o’clock position (Fig. 59). Rotate the can result in a vehicle no start condition.
crankshaft one turn if necessary.
(13) Remove the crankshaft damper. Refer to
Crankshaft Damper in this section.

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 DN 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. Discard not damage the tensioner arm or the guide arm.
the gasket.
(3) Position the cylinder head onto the cylinder
CAUTION: Do not lay the cylinder head on its gas- block. Make sure the cylinder head seats fully over
ket sealing surface, do to the design of the cylinder the locating dowels.
head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop- NOTE: The four smaller cylinder head mounting
erly sealing resulting in leaks. bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.

INSTALLATION (4) Lubricate the cylinder head bolt threads with

clean engine oil and install the ten M10 bolts.
NOTE: The cylinder head bolts are tightened using (5) Coat the four M8 cylinder head bolts with
a torque plus angle procedure. The bolts must be Mopar Lock and Seal Adhesive then install the
examined BEFORE reuse. If the threads are necked bolts.
down the bolts should be replaced.
NOTE: The cylinder head bolts are tightened using
Necking can be checked by holding a straight edge an angle torque procedure, however, the bolts are
against the threads. If all the threads do not contact not a torque-to-yield design.
the scale, the bolt should be replaced (Fig. 61).
(6) Tighten the bolts in sequence (Fig. 66) using
CAUTION: When cleaning cylinder head and cylin- the following steps and torque values:
der block surfaces, DO NOT use a metal scraper • Step 1: Tighten bolts 1–10, 20 N·m (15 ft. lbs.).
because the surfaces could be cut or ground. Use • Step 2: Tighten bolts 1–10, 47 N·m (35 ft. lbs.).
only a wooden or plastic scraper. Tighten bolts 11–14, 25 N·m (18 ft. lbs.).
• Step 3: Tighten bolts 1–10, 90 degrees. Tighten
(1) Clean the cylinder head and cylinder block bolts 11–14, 30 N·m (22 ft. lbs.).
mating surfaces (Fig. 65).

Fig. 66 Cylinder Head Tightening Sequence

(7) Position the secondary chain onto the camshaft
drive gear, making sure one marked chain link is on
either side of the V8 mark on the gear and position
the gear onto the camshaft.
(8) Install the camshaft drive gear retaining bolt.
(9) Install the right side secondary chain guide.
(10) Install the cylinder head access plug.
Fig. 65 Proper Tool Usage For Surface Preparation (11) Re-set and install the right side secondary
1 – PLASTIC/WOOD SCRAPER
chain tensioner.
(12) Remove Special Tool 8515.
(13) Install the timing chain cover.

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 9 - 46 4.7L ENGINE DN
REMOVAL AND INSTALLATION (Continued)
(14) Install the 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.
(16) Install the fan shroud.
(17) Install the cylinder head cover. (6) Using Special Tool 8387 Valve Spring Compres-
(18) Install the intake manifold. sor, compress the valve spring.
(19) Install oil fill housing onto cylinder head.
(20) Refill the cooling system. NOTE: It may be necessary to tap the top of the
(21) Raise the vehicle. valve spring to loosen the spring retainers locks
(22) Install the exhaust pipe onto the right enough to be removed.
exhaust manifold.
(7) Remove the two spring retainer lock halves.
(23) Lower the vehicle.
(24) Reconnect battery negitive cable. NOTE: the valve spring is under tension use care
(25) Start the engine and check for leaks. when releasing the valve spring compressor.

VALVE SPRINGS AND SEALS (8) Remove the valve spring compressor.
(9) Remove the spring retainer, and the spring.
REMOVAL (10) Remove the valve stem seal.
(1) Remove the cylinder head cover. Refer to Cyl-
inder Head Cover in this Section. NOTE: The valve stem seals are common between
(2) Using Special Tool 8516 Valve Spring Compres- intake and exhaust.
sor, remove the rocker arms and the hydraulic lash
adjusters (Fig. 67).
INSTALLATION
(1) coat the valve stem with clean engine oil and
install the valve stem seal. make sure the seal is
fully seated and that the garter spring at the top of
the seal is intact.
(2) Install the spring and the spring retainer.
(3) Using Special Tool 8387 Valve Spring Compres-
sor, compress the spring and install the two valve
spring retainer halves.
(4) Release the valve spring compressor and make
sure the two spring retainer halves and the spring
retainer are fully seated.
(5) Install the camshaft. Refer to Camshaft in this
section.
(6) Position the hydraulic lash adjusters and
rocker arms (Fig. 67).
(7) Install the cylinder head cover.

HYDRAULIC LASH ADJUSTER

REMOVAL
(1) Remove cylinder head cover(s). Refer to proce-
dure in this section.
Fig. 67 Rocker Arm—Removal (2) Remove rocker arm(s). Refer to procedure in
1 – CAMSHAFT this section.
2 – SPECIAL TOOL 8516
CAUTION: If lash adjusters and rocker arms are to
(3) Remove the spark plug for the cylinder the be reused, always mark position for reassembly in
valve spring and seal are to be removed from. their original positions.
(4) Apply shop air to the cylinder to hold the
(3) Remove lash adjuster(s).
valves in place when the spring is removed
(5) Remove the camshaft. Refer to Camshaft in
this section.

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 DN 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 – FAN
4 – INTAKE VALVE
5 – EXHAUST VALVE
6 – VALVE SPRING NOTE: Transmission cooler line snaps into shroud
lower right hand corner.

INSTALLATION (9) Remove crankshaft damper bolt.

(1) Install hydraulic lash adjuster making sure (10) Remove damper using Special Tools 8513
adjusters are at least partially full of oil. This can be Insert and 1026 Three Jaw Puller (Fig. 70).
verified by little or no plunger travel when lash
adjuster is depressed. INSTALLATION
(2) Install rocker arm(s). Refer to procedure in this
section. CAUTION: To prevent severe damage to the Crank-
(3) Install cylinder head cover(s). Refer to proce- shaft, Damper or Special Tool 8512, thoroughly
dure in this section. clean the damper bore and the crankshaft nose
before installing Damper.
CRANKSHAFT DAMPER
(1) Align crankshaft damper slot with key in
REMOVAL crankshaft. Slide damper onto crankshaft slightly.
(1) Disconnect negative cable from battery.
CAUTION: Special Tool 8512, is assembled in a
(2) Remove accessory drive belt. Refer to COOL-
specific sequence. Failure to assemble this tool in
ING SYSTEM.
this sequence can result in tool failure and severe
(3) Drain cooling system. Refer to COOLING SYS-
damage to either the tool or the crankshaft.
TEM.
(4) Remove radiator upper hose. (2) Assemble Special Tool 8512 as follows, The nut
(5) Remove upper fan shroud. Refer to COOLING is threaded onto the shaft first. Then the roller bear-
SYSTEM. ing is placed onto the threaded rod (The hardened
(6) Using Special Tools 6958 Spanner with Adapter bearing surface of the bearing MUST face the nut).
Pins 8346, loosen fan and viscous assembly from Then the hardened washer slides onto the threaded
water pump (Fig. 69). rod (Fig. 71). Once assembled coat the threaded rod’s
(7) Remove fan and viscous assembly. threads with Mopart Nickel Anti-Seize or (Loctite
(8) Disconnect electrical connector for fan mounted No. 771).
inside radiator shroud.

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 9 - 48 4.7L ENGINE DN
REMOVAL AND INSTALLATION (Continued)

Fig. 70 Crankshaft Damper—Removal Fig. 72 Crankshaft Damper—Installation

1 – SPECIAL TOOL 8513 INSERT 1 – SPECIAL TOOL 8512
2 – SPECIAL TOOL 1026

(6) Install radiator upper shroud and tighten fas-

teners to 11 N·m (95 in. lbs.).
(7) Connect electrical connector for shroud fan.
(8) Install radiator upper hose.
(9) Install accessory drive belt.
(10) Refill cooling system.
(11) Connect negative cable to battery.

TIMING CHAIN COVER

REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system and remove viscous fan
drive assembly. Refer to Group 7, Cooling System for
procedures.
(3) Remove radiator shroud. Refer to Group 7,
Cooling System for procedure.
Fig. 71 Proper Assembly Method for Special Tool (4) Disconnect both heater hoses at timing cover.
8512 (5) Disconnect lower radiator hose at engine.
1 – BEARING (6) Remove crankshaft damper. Refer to procedure
2 – NUT in this section.
3 – THREADED ROD (7) Remove accessory drive belt tensioner assembly
4 – BEARING HARDENED SURFACE (FACING NUT) (Fig. 73).
5 – HARDENED WASHER (8) Remove the generator and A/C compressor.
(9) Remove cover and gasket (Fig. 74).
(3) Using Special Tool 8512, press damper onto
crankshaft (Fig. 72).
INSTALLATION
(4) Install then tighten crankshaft damper bolt to (1) Clean timing chain cover and block surface.
175 N·m (130 ft. lbs.). Inspect cover gasket and replace as necessary.
(5) Install fan blade assembly. (2) Install cover and gasket. Tighten fasteners in
sequence as shown in (Fig. 74) to 54 N·m (40 ft. lbs.).

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 DN 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.
(3) Remove right and left cylinder head covers.
Refer to procedure in this section.
(4) Remove radiator fan shroud. Refer to Group 7,
Cooling System for procedure.
(5) Rotate engine until timing mark on crankshaft
damper aligns with TDC mark on timing chain cover
(Fig. 75) (#1 cylinder exhaust stroke) and the cam-
shaft sprocket “V8” marks are at the 12 o’clock posi-
tion (Fig. 76).

Fig. 73 Accessory Drive Belt Tensioner

1 – TENSIONER ASSEMBLY
2 – FASTENER TENSIONER TO FRONT COVER

Fig. 75 Engine Top Dead Center (TDC) Indicator

Mark
1 – TIMING CHAIN COVER
2 – CRANKSHAFT TIMING MARKS
Fig. 74 Timing Chain Cover Fasteners
(3) Install the A/C compressor and generator. (6) Remove power steering pump. Refer to Group
(4) Install crankshaft damper. Refer to procedure 19, Steering for procedures.
in this section. (7) Remove access plugs (2) from left and right cyl-
(5) Install accessory drive belt tensioner assembly. inder heads for access to chain guide fasteners (Fig.
Tighten fastener to 54 N·m (40 ft. lbs.). 77).
(6) Install lower radiator hose. (8) Remove the oil fill housing to gain access to the
(7) Install both heater hoses. right side tensioner arm fastener.
(8) Install radiator shroud and viscous fan drive (9) Remove crankshaft damper and timing chain
assembly. Refer to Group 7, Cooling System for pro- cover. Refer to procedures in this section.
cedure.

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 9 - 50 4.7L ENGINE DN
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. 78 Collapsing And Pinning Primary Chain

(10) Collapse and pin primary chain tensioner Tensioner
(Fig. 78). 1 – PRIMARY CHAIN TENSIONER
2 – ADJUSTABLE PLIERS
CAUTION: Plate behind left secondary chain ten- 3 – SPECIAL TOOL 8514
sioner could fall into oil pan. Therefore, cover pan
opening.

(11) Remove secondary chain tensioners.

(12) Remove camshaft position sensor from right
cylinder head (Fig. 79).

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 DN 4.7L ENGINE 9 - 51
REMOVAL AND INSTALLATION (Continued)

Fig. 79 Camshaft Position Sensor—Removal

1 – CRANKSHAFT POSITION SENSOR
Fig. 80 Camshaft Rotation—Left Side
2 – CYLINDER HEAD COVER 1 – CAMSHAFT SPROCKET AND CHAIN
3 – CAMSHAFT POSITION SENSOR 2 – ADJUSTABLE PLIERS
4 – RIGHT SIDE CYLINDER BLOCK 3 – CAMSHAFT

CAUTION: Care should be taken not to damage

camshaft target wheel. Do not hold target wheel
while loosening or tightening camshaft sprocket.
Do not place the target wheel near a magnetic
source of any kind. A damaged or magnetized tar-
get wheel could cause a vehicle no start condition.

CAUTION: Do not forcefully rotate the camshafts or

crankshaft independently of each other. Damaging
intake valve to piston contact will occur. Ensure
negative battery cable is disconnected to guard
against accidental starter engagement.

(13) Remove left and right camshaft sprocket bolts.

(14) While holding the left camshaft steel tube
with adjustable pliers, (Fig. 80) remove the left cam-
shaft sprocket. Slowly rotate the camshaft approxi-
mately 15 degrees clockwise to a neutral position.
(15) While holding the right camshaft steel tube
with adjustable pliers, (Fig. 81) remove the right
camshaft sprocket. Slowly rotate the camshaft
approximately 45 degrees counterclockwise to a neu-
tral position. Fig. 81 Camshaft Rotation—Right Side
(16) Remove idler sprocket assembly bolt. 1 – ADJUSTABLE PLIERS
2 – CAMSHAFT DOWEL
(17) Slide the idler sprocket assembly and crank
sprocket forward simultaneously to remove the pri-
mary and secondary chains. (19) Remove chain tensioner.
(18) Remove both pivoting tensioner arms and
chain guides.

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 9 - 52 4.7L ENGINE DN
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 – CRANKSHAFT SPROCKET
4 – LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN 10 – PRIMARY CHAIN TENSIONER
5 – CHAIN GUIDE 11 – TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
6 – TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN 12 – SECONDARY TENSIONER ARM

INSPECTION OF COMPONENTS • Primary chain tensioner plastic faces. Replace as

Inspect the following components: required.
• Sprockets for excessive tooth wear. Some tooth
markings are normal and not a cause for sprocket INSTALLATION
replacement. (1) Using a vise, lightly compress the secondary
• Idler sprocket assembly bushing and shaft for chain tensioner piston until the piston step is flush
excessive wear. with the tensioner body. Using a pin or suitable tool,
• Idler sprocket assembly spline joint. The joint release ratchet pawl by pulling pawl back against
should be tight with no backlash or axial movement. spring force through access hole on side of tensioner.
• Chain guides and tensioner arms. Replace these While continuing to hold pawl back, Push ratchet
parts if grooving in plastic face is more than 1 mm device to approximately 2 mm from the tensioner
(0.039 in.) deep. If plastic face is severely grooved or body. Install Special Tool 8514 lock pin into hole on
melted, the tensioner lube jet may be clogged. The front of tensioner. Slowly open vise to transfer piston
tensioner should be replaced. spring force to lock pin (Fig. 83).
• secondary chain tensioner piston and ratcheting (2) Position primary chain tensioner over oil pump
device. Inspect for evidence of heavy contact between and insert bolts into lower two holes on tensioner
tensioner piston and tensioner arm. If this condition bracket. Tighten bolts to 28 N·m (250 in. lbs.).
exist the tensioner tensioner arm and chain should
be replaced.

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 DN 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. 82).

Fig. 83 Resetting Secondary Chain Tensioners

1 – VISE
2 – INSERT LOCK PIN
3 – RATCHET PAWL
4 – RATCHET
5 – PISTON Fig. 84 Installing Secondary Timing Chains on Idler
Sprocket
CAUTION: Overtightening the tensioner arm torxT 1 – LOCK ARM
2 – RIGHT CAMSHAFT CHAIN
bolt can cause severe damage to the cylinder head.
3 – SECONDARY CHAINS RETAINING PINS (4)
Tighten torxT bolt to specified torque only.
4 – IDLER SPROCKET
5 – LEFT CAMSHAFT CHAIN
(3) Install right side chain tensioner arm. Apply
6 – SPECIAL TOOL 8515
Mopart Lock N, Seal to torxt bolt, tighten bolt to 17
N·m (150 in. lbs.).
(9) Lubricate idler shaft and bushings with clean
NOTE: The silver bolts retain the guides to the cyl- engine oil.
inder heads and the black bolts retain the guides to (10) Install all chains, crankshaft sprocket, and
the engine block. idler sprocket as an assembly (Fig. 85). After guiding
both secondary chains through the block and cylinder
(4) Install the left side chain guide. Tighten the head openings, affix chains with a elastic strap or the
bolts to 28 N·m (250 in. lbs.). equivalent, This will maintain tension on chains to
aid in installation.
CAUTION: Overtightening the tensioner arm torxT
bolt can cause severe damage to the cylinder head. NOTE: It will be necessary to slightly rotate cam-
Tighten torxT bolt to specified torque only. shafts for sprocket installation.
(5) Install left side chain tensioner arm. Apply (11) Align left camshaft sprocket “L” dot to plated
Mopart Lock N, Seal to torxt bolt, tighten bolt to 17 link on chain.
N·m (150 in. lbs.). (12) Align right camshaft sprocket “R” dot to
(6) Install the right side chain guide. Tighten the plated link on chain.
bolts to 28 N·m (250 in. lbs.).
(7) Install both secondary chains onto the idler CAUTION: Remove excess oil from the camshaft
sprocket. Align two plated links on the secondary sprocket bolt. Failure to do so can result in over-
chains to be visible through the two lower openings torque of bolt resulting in bolt failure.
on the idler sprocket (4 o’clock and 8 o’clock). Once

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 9 - 54 4.7L ENGINE DN
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. Remove excess oil from bolts,
then Install sprocket bolts, but do not tighten at this
time. Fig. 86 Tightening Left Side Camshaft Sprocket Bolt
(14) Verify that all plated links are aligned with 1 – TORQUE WRENCH
the marks on all sprockets and the “V8” marks on 2 – CAMSHAFT SPROCKET
3 – LEFT CYLINDER HEAD
camshaft sprockets are at the 12 o’clock position (Fig.
4 – SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
82).

CAUTION: Ensure the plate between the left sec- (19) Rotate engine two full revolutions. Verify tim-
ondary chain tensioner and block is correctly ing marks are at the follow locations:
installed. • primary chain idler sprocket dot is at 12 o’clock
(Fig. 82)
(15) Install both secondary chain tensioners. • primary chain crankshaft sprocket dot is at 6
Tighten bolts to 28 N·m (250 in. lbs.). o’clock (Fig. 82)
• secondary chain camshaft sprockets “V8” marks
NOTE: Left and right secondary chain tensioners
are at 12 o’clock (Fig. 82)
are not common.
(20) Lubricate all three chains with engine oil.
(16) Before installing idler sprocket bolt, lubricate (21) After installing all chains, it is recommended
washer with oil, and tighten idler sprocket assembly that the idler gear end play be checked (Fig. 88). The
retaining bolt to 34 N·m (25 ft. lbs.). end play must be within 0.10–0.25 mm (0.004–0.010
(17) Remove all locking pins (3) from tensioners. in.). If not within specification, the idler gear must be
replaced.
CAUTION: After pulling locking pins out of each (22) Install timing chain cover and crankshaft
tensioner, DO NOT manually extend the tensioner(s) damper. Refer to procedures in this section.
ratchet. Doing so will over tension the chains, (23) Install cylinder head covers. Refer to proce-
resulting in noise and/or high timing chain loads. dures in this section.

(18) Using Special Tool 6958, Spanner with Adap- NOTE: Before installing threaded plug in right cyl-
tor Pins 8346, tighten left (Fig. 86) and right (Fig. inder head, the plug must be coated with sealant to
87). camshaft sprocket bolts to 122 N·m (90 ft. lbs.). prevent leaks.

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 DN 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.
(29) Fill cooling system. Refer to Group 7, Cooling
System for coolant fill procedure.
(30) Connect negative cable to battery.

IDLER SHAFT—TIMING DRIVE

REMOVAL
(1) Remove the timing chain and sprockets. Refer
to procedure in this section.

NOTE: To remove the idler shaft, it is necessary to

tap threads into the shaft to install the removal tool.
Fig. 87 Tightening Right Side Camshaft Sprocket (2) Using a 12 mm X 1.75 tap, cut threads in the
Bolt idler shaft center bore (Fig. 89).
1 – TORQUE WRENCH
2 – SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 – LEFT CAMSHAFT SPROCKET
4 – RIGHT CAMSHAFT SPROCKET

Fig. 89 Tapping Idler Shaft For Special Tool 8517

1 – IDLER SHAFT
2 – TAP 12mm X 1.75

(3) Cover the radiator core with a suitable cover.

Fig. 88 Measuring Idler Gear End Play
1 – IDLER SPROCKET ASSEMBLY CAUTION: Use care when removing idler shaft, DO
2 – DIAL INDICATOR NOT strike the radiator cooling fins with the slide
hammer.
(24) Coat the large threaded access plug with
(4) Using Special Tool 8517 Slide Hammer, remove
Mopart Thread Sealant with Teflon, then install
the idler shaft (Fig. 90).
into the right cylinder head and tighten to 81 N·m
(60 ft. lbs.) (Fig. 77).

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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.

(1) Remove cylinder head cover. Refer to Cylinder

Head Cover in this section.
(2) Set engine to TDC cylinder #1, camshaft
sprocket V8 marks at the 12 o’clock position.
(3) Mark one link on the secondary timing chain
on both sides of the V8 mark on the camshaft
sprocket to aid in installation.

CAUTION: Do not hold or pry on the camshaft tar-

get wheel (Located on the right side camshaft
sprocket) for any reason, Severe damage will occur
to the target wheel resulting in a vehicle no start
condition.

(4) Loosen but DO NOT remove the camshaft

sprocket retaining bolt. Leave the bolt snug against
Fig. 90 Removing Idler Shaft the sprocket.
1 – IDLER SHAFT
2 – SPECIAL TOOL 8517 NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
INSTALLATION ers to extend, requiring timing chain cover removal
(1) Thoroughly clean the idler shaft bore. in order to reset tensioners.
(2) Position the idler shaft in the bore.

NOTE: The two lubrication holes in the idler shaft CAUTION: Do not force wedge past the narrowest
do not require any special alignment. point between the chain strands. Damage to the
tensioners may occur.
NOTE: Before using the retaining bolt to install the (5) Position Special Tool 8350 timing chain wedge
idler shaft, coat the threads and the pilot on the between the timing chain strands, tap the tool to
idler shaft with clean engine oil. securely wedge the timing chain against the ten-
sioner arm and guide (Fig. 91).
(3) Using the primary idler sprocket retaining bolt (6) Hold the camshaft with adjustable pliers while
and washer, carefully draw the idler shaft into the removing the camshaft sprocket bolt and sprocket
bore until fully seated. (Fig. 92).
(4) Coat the idler shaft with clean engine oil and (7) Using the pliers, gently allow the camshaft to
install the timing chains and sprockets. Refer to pro- rotate 15° clockwise until the camshaft is in the neu-
cedure in this section. tral position (no valve load).
(8) Starting at the outside working inward, loosen
CAMSHAFTS—IN VEHICLE the camshaft bearing cap retaining bolts 1/2 turn at
a time. Repeat until all load is off the bearing caps.
LEFT CAMSHAFT
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
REMOVAL SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen- NOTE: When the camshaft is removed the rocker
dently of each other. Severe valve and/or piston arms may slide downward, mark the rocker arms
damage can occur. before removing camshaft.

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 DN 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.

NOTE: Position the left side camshaft so that the

camshaft sprocket dowel is near the 1 o’clock posi-
tion, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.

(2) Position the camshaft into the cylinder head.

(3) Install the camshaft bearing caps, hand tighten
the retaining bolts.
(4) Working in 1⁄2 turn increments, tighten the
bearing cap retaining bolts starting with the middle
cap working outward (Fig. 93).
(5) Torque the camshaft bearing cap retaining
bolts to 11 N·m (100 in. lbs.).
(6) Position the camshaft drive gear into the tim-
ing chain aligning the V8 mark between the two
marked chain links (Two links marked during
removal) (Fig. 94).
Fig. 92 Camshaft Sprocket and Chain (7) Using the adjustable pliers, rotate the cam-
1 – CAMSHAFT SPROCKET AND CHAIN shaft until the camshaft sprocket dowel is aligned
2 – ADJUSTABLE PLIERS with the slot in the camshaft sprocket. Install the
3 – CAMSHAFT sprocket onto the camshaft (Fig. 95).

(9) Remove the camshaft bearing caps and the

camshaft.

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 9 - 58 4.7L ENGINE DN
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. 96), torque the camshaft
sprocket retaining bolt to 122 N·m (90 ft. lbs.).
(11) Install the cylinder head cover.

RIGHT CAMSHAFT
REMOVAL

CAUTION: When the timing chain is removed and

the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.

CAUTION: When removing the cam sprocket, tim-

ing chains or camshaft, Failure to use special tool
8350 will result in hydraulic tensioner ratchet over
Fig. 93 Camshaft Bearing Caps Tightening extension, Requiring timing chain cover removal to
Sequence re-set the tensioner ratchet.
CAUTION: Remove excess oil from camshaft
sprocket bolt. Failure to do so can cause bolt over- (1) Remove the cylinder head covers. Refer to Cyl-
torque resulting in bolt failure. inder Head Cover in this section.

Fig. 94 Timing Chain to Sprocket Alignment

1 – LEFT CYLINDER HEAD
2 – RIGHT CYLINDER HEAD

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 DN 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.
(3) Mark one link on the secondary timing chain Fig. 96 Tightening Left Side Cam Sprocket
on both sides of the V8 mark on the camshaft Retaining Bolt
sprocket to aid in installation. 1 – TORQUE WRENCH
2 – CAMSHAFT SPROCKET
CAUTION: Do not hold or pry on the camshaft tar- 3 – LEFT CYLINDER HEAD
4 – SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
get wheel for any reason, Severe damage will occur
to the target wheel. A damaged target wheel could
cause a vehicle no start condition. (7) Hold the camshaft with adjustable pliers while
removing the camshaft sprocket bolt and sprocket
(4) Loosen but DO NOT remove the camshaft (Fig. 99).
sprocket retaining bolt. Leave bolt snug against (8) Using the pliers, gently allow the camshaft to
sprocket. rotate 45° counter-clockwise until the camshaft is in
the neutral position (no valve load).
NOTE: The timing chain tensioners must be (9) Starting at the outside working inward, loosen
secured prior to removing the camshaft sprockets. the camshaft bearing cap retaining bolts 1/2 turn at
Failure to secure tensioners will allow the tension- a time. Repeat until all load is off the bearing caps.
ers to extend, requiring timing chain cover removal
in order to reset tensioners. CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur. NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
(5) Position Special Tool 8350 timing chain wedge before removing camshaft.
between the timing chain strands. Tap the tool to
securely wedge the timing chain against the ten- (10) Remove the camshaft bearing caps and the
sioner arm and guide (Fig. 97). camshaft.
(6) Remove the camshaft position sensor (Fig. 98).

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 9 - 60 4.7L ENGINE DN
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. 98 Camshaft Position Sensor Fig. 99 Camshaft Sprocket and Chain

1 – CRANKSHAFT POSITION SENSOR 1 – ADJUSTABLE PLIERS
2 – CYLINDER HEAD COVER 2 – SPROCKET BOLT
3 – CAMSHAFT POSITION SENSOR 3 – CAMSHAFT SPROCKET AND CHAIN
4 – RIGHT SIDE CYLINDER BLOCK 4 – CAMSHAFT

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 DN 4.7L ENGINE 9 - 61
REMOVAL AND INSTALLATION (Continued)
INSTALLATION (8) Remove excess oil from camshaft sprocket bolt,
(1) Lubricate camshaft journals with clean engine then install the camshaft sprocket retaining bolt and
oil. hand tighten.
(9) Remove timing chain wedge special tool 8350
NOTE: Position the right side camshaft so that the (Fig. 97).
camshaft sprocket dowel is near the 10 o’clock (10) Using Special Tool 6958 spanner wrench with
position, This will place the camshaft at the neutral adapter pins 8346 (Fig. 103), torque the camshaft
position easing the installation of the camshaft sprocket retaining bolt to 122 N·m (90 ft. lbs.).
bearing caps. (11) Install the camshaft position sensor (Fig. 98).
(12) Install the cylinder head cover.
(2) Position the camshaft into the cylinder head.
(3) Install the camshaft bearing caps, hand tighten CRANKSHAFT MAIN BEARINGS
the retaining bolts.
(4) Working in 1/2 turn increments, tighten the CRANKSHAFT MAIN BEARING SELECTION
bearing cap retaining bolts starting with the middle The main bearings are “select fit” to achieve proper
cap working outward (Fig. 100). oil clearances. For main bearing selection, the crank-
shaft position sensor target wheel has grade identifi-
cation marks stamped into it (Fig. 104). These marks
are read from left to right, corresponding with jour-
nal number 1, 2, 3, 4 and 5. The crankshaft position
sensor target wheel is mounted to the number 8
counter weight on the crankshaft.

NOTE: Service main bearings color coded. These

color codes identify what size (grade) the bearing
is.

CHECKING CRANKSHAFT END PLAY

(1) Mount a dial indicator to a stationary point at
front of engine. Locate the probe perpendicular
against nose of crankshaft (Fig. 105).
(2) Move the crankshaft all the way to the rear of
it’s travel.
(3) Zero the dial indicator.
(4) Move the crankshaft all the way to the front of
it’s travel and read the dial indicator. Refer to Crank-
shaft End Play Specification Chart.
Fig. 100 Camshaft Bearing Caps Tightening
Sequence
OIL PAN 4X2 VEHICLE
(5) Torque the camshaft bearing cap retaining REMOVAL
bolts to 11 N·m (100 in. lbs.). (1) Drain the cooling system. Refer to COOLING
(6) Position the camshaft drive gear into the tim- SYSTEM.
ing chain aligning the V8 mark between the two (2) Remove the upper fan shroud. Refer to proce-
marked chain links (Two links marked during dure in this section.
removal) (Fig. 101). (3) Remove the throttle body resonator and air
(7) Using the adjustable pliers, rotate the cam- inlet hose.
shaft until the camshaft sprocket dowel is aligned (4) Remove the intake manifold. Refer to proce-
with the slot in the camshaft sprocket. Install the dure in this section.
sprocket onto the camshaft (Fig. 102). (5) Raise vehicle on hoist.
(6) Disconnect exhaust pipe at exhaust manifolds.
CAUTION: Remove excess oil from camshaft Refer to EXHAUST SYSTEM.
sprocket bolt. Failure to do so can cause bolt over- (7) Remove the structural dust cover (Fig. 106).
torque resulting in bolt failure. Refer to procedure in this section.
(8) Drain engine oil and remove oil filter.
(9) Position suitable jack under engine.

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 9 - 62 4.7L ENGINE DN
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 – SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
1 – ADJUSTABLE PLIERS 3 – LEFT CAMSHAFT SPROCKET
2 – CAMSHAFT DOWEL 4 – RIGHT CAMSHAFT SPROCKET

(10) Remove both left and right side engine mount (11) Raise engine to provide clearance to remove
through bolts (Fig. 107). oil pan.

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 DN 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
2 – TARGET WHEEL Specification (0.002 - 0.011 in.)
3 – MAIN BEARING SELECT FIT MARKINGS
Wear Limit: 0.43mm
(0.017 in.)
MAIN BEARING SELECTION CHART—4.7L

GRADE SIZE mm FOR USE WITH

(in.)
MARKING JOURNAL SIZE

A 0.008 mm 63.488–63.496 mm
U/S
(0.0004 in.) (2.4996–2.4999 in.)
U/S

B NOMINAL 63.496–63.504 mm
(2.4999–2.5002 in.)

C 0.008 mm 63.504–63.512 mm
O/S
(0.0004 in.) (2.5002–2.5005 in.)
O/S Fig. 106 Structural Dust Cover Removal /
Installation
(12) Place blocks of wood between engine brackets INSTALLATION
and lower mounts to provide stability to engine. (1) Clean the oil pan gasket mating surface of the
bedplate and oil pan.
NOTE: Do not pry on oil pan or oil pan gasket. (2) Position the oil pan gasket and pickup tube
Gasket is mounted to engine and does not come with new o-ring. Install the mounting bolt and nuts.
out with oil pan. Tighten bolt and nuts to 28 N·m (20 ft. lbs.).
(3) Position the oil pan and install the mounting
(13) Remove the oil pan mounting bolts and oil
bolts. Tighten the mounting bolts to 15 N·m (11 ft.
pan (Fig. 108).
lbs.) in the sequence shown (Fig. 108).
(14) Unbolt oil pump pickup tube and remove tube
(4) Raise the engine and remove the blocks of
and oil pan gasket from engine.
wood.

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 9 - 64 4.7L ENGINE DN
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. Refer to

DIFFERENTIAL AND DRIVELINE.
(2) Remove the structural dust cover (Fig. 109).
Refer to procedure in this section.

Fig. 107 Engine Mount Through Bolt and Nut

Removal / Installation
1 – LOCKNUT AND WASHER
2 – ENGINE MOUNT/INSULATOR
3 – THROUGH BOLT
4 – FRAME

Fig. 109 Structural Dust Cover Removal /

Installation
(3) Drain the engine oil and remove oil filter.

NOTE: Do not pry on oil pan or oil pan gasket.

Gasket is mounted to engine and does not come
out with oil pan.

(4) Remove the oil pan mounting bolts and oil pan
(Fig. 110).

Fig. 108 Oil Pan Mounting Bolts and Oil Pan

(5) Lower engine and install both the left and
right side engine mount through bolts (Fig. 107).
Tighten the nuts to 68 N·m (50 ft. lbs.).
(6) Remove jack and install oil filter.
(7) Install structural dust cover.
(8) Install exhaust pipe onto exhaust manifolds.
(9) Lower vehicle.
(10) Install intake manifold.
(11) Install throttle body resonator and air inlet
hose.
(12) Install upper fan shroud. Fig. 110 Oil Pan Mounting Bolts and Oil Pan
(13) Fill cooling system.
(5) Unbolt oil pump pickup tube and remove tube
(14) Fill engine oil.
and oil pan gasket from engine.

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 DN 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. 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. Fig. 111 Identify Connecting Rod to Cylinder
(7) Lower vehicle. Position—Typical
(8) Fill engine oil. CAUTION: Care must be taken not to nick crank-
(9) Start engine check for leaks. shaft journals, as engine damage may occur

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

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 9 - 66 4.7L ENGINE DN
REMOVAL AND INSTALLATION (Continued)

Fig. 112 Side Rail—Installation Fig. 114 Piston Ring End Gap Position
1 – SIDE RAIL END 1 – SIDE RAIL UPPER
2 – NO. 1 RING GAP
3 – PISTON PIN
4 – SIDE RAIL LOWER
5 – NO. 2 RING GAP AND SPACER EXPANDER GAP

Fig. 113 Upper and Intermediate Rings—Installation

(2) Immerse the piston head and rings in clean
engine oil. Position a ring compressor over the piston
and rings. Tighten ring compressor. Ensure posi-
tion of rings do not change during this opera-
tion.
(3) Position bearing onto connecting rod. Ensure
that hole in bearing shell aligns with hole in connect-
ing rod. Lubricate bearing surface with clean engine
oil.
(4) Install Special Tool 8507 Connecting Rod
Guides into connecting rod bolt threads (Fig. 115).
(5) The pistons are marked on the piston pin bore
surface with an raised “F” indicating installation
position. This mark must be pointing toward the
front of engine on both cylinder banks. The connect- Fig. 115 Piston and Connecting Rod—Installation
ing rod oil slinger slot faces the front of the engine 1 – “F” TOWARD FRONT OF ENGINE
(Fig. 116). 2 – OIL SLINGER SLOT
(6) Wipe cylinder bore clean and lubricate with 3 – RING COMPRESSOR
engine oil. 4 – SPECIAL TOOL 8507

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 DN 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. Refer to Oil
Pump in this section for procedure.

CAUTION: DO NOT pry on the oil pan gasket when

removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.

(3) Remove oil pan bolts and oil pan.

(4) Remove the oil pump pickup tube and oil pan
gasket /windage tray.
(5) Remove the bedplate mounting bolts. Note the
location of the three stud bolts for installation.
Fig. 116 Piston and Connecting Rod Positioning (6) Remove the connecting rods from the crank-
1 – MAJOR THRUST SIDE OF PISTON shaft.
2 – OIL SLINGER SLOT
CAUTION: The bedplate to cylinder block mating
surface is a critical sealing surface. Do not pry on
(7) Rotate crankshaft until connecting rod journal
or damage this surface in anyway.
is on the center of cylinder bore. Insert rod and pis-
ton into cylinder bore and carefully position connect-
ing rod guides over crankshaft journal. NOTE: The bedplate contains the lower main bear-
(8) Tap piston down in cylinder bore using a ham- ing halves. Use care when handling bedplate as not
mer handle. While at the same time, guide connect- to drop or damage bearing halves. Installing main
ing rod into position on rod journal. bearing halves in the wrong position will cause
sever damage to the crankshaft.
CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened NOTE: The bedplate has pry points cast into it. Use
or removed. these points only. The pry points are on both the
left and right sides, only the left side is shown.
(9) Lubricate rod bolts and bearing surfaces with
engine oil. Install connecting rod cap and bearing. (7) Carefully pry on the pry points (Fig. 117) to
Tighten bolts to 27 N·m (20 ft. lbs.) plus 90°. loosen the bedplate then remove the bedplate.
(10) Install the following components: (Refer to
procedures in this section) CAUTION: When removing the crankshaft, use care
• Cylinder head(s). not to damage bearing surfaces on the crankshaft.
• Timing chain and cover.
• Cylinder head covers. (8) Remove the crankshaft.
• Oil pan and gasket/windage tray. (9) Remove the crankshaft tone wheel.
(11) Fill crankcase with proper engine oil to cor-
rect level. INSPECTION
(12) Connect negative cable to battery.
NOTE: Thoroughly inspect the connecting rod
bearing bores and main bearing bores for scoring,
blueing or severe scratches. Further disassembly
may be required.

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 9 - 68 4.7L ENGINE DN
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.

(2) Install the crankshaft tone wheel. torque the

mounting screws to 22 N·m (21 ft. lbs.).
(3) Install the thrust washer (Fig. 118).

Fig. 117 Bedplate Pry Point Location

1 – CYLINDER BLOCK
2 – BEDPLATE
3 – PRY POINT

If connecting rod bearing bores show damage, the

cylinder heads must be removed to service the piston
and rod assemblies. If the bedplate or the cylinder Fig. 118 Crankshaft Thrust Washer Installation
block main bearing bores show damage the engine 1 – CRANKSHAFT THRUST WASHER
must be replaced.
(1) If required, remove the main bearing halves
from the cylinder block and bedplate. (4) Position crankshaft in cylinder block.
(2) Thoroughly clean the bedplate to cylinder block
CAUTION: The bedplate to cylinder block mateing
sealing surfaces and main bearing bores. Remove all
surface must be coated with sealant prior to instal-
oil and sealant residue.
lation. Failure to do so will cause severe oil leaks.
(3) Inspect the bedplate main bearing bores for
cracks, scoring or severe blueing. If either condition
exists the engine must be replaced. NOTE: The installation time to install the bedplate
(4) Inspect the crankshaft thrust washer for scor- after the sealant has been applied is critical.
ing, scratches or blueing. If either condition exist
replace the thrust washer.
(5) Inspect the oil pan gasket/windage tray for NOTE: Make sure that the bedplate and cylinder
splits, tears or cracks in the gasket sealing surfaces. block sealing surfaces are clean and free of oil or
Replace gasket as necessary. other contaminants. Contaminants on the sealing
surfaces may cause main bearing distortion and/or
INSTALLATION oil leaks.

CAUTION: Main bearings are select fit. Refer to (5) Apply a 2.5mm (0.100 inch) (Fig. 119) bead of
Crankshaft Main Bearings in this section for proper Mopart Gen II Silicone Rubber Adhesive sealant to
bearing selections. the cylinder block-to-bedplate mating surface as
shown (Fig. 120).

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 DN 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. Refer to Connecting Rod Bearings in this
section for procedure.
(10) Position the oil pan gasket/windage tray,
using a new o-ring, install the oil pickup tube.
Torque the bolt to 28N·n (20 ft. lbs.) torque the nuts
to 28N·m (20 ft. lbs.).
(11) Install the oil pan. Torque the retaining bolts
to 15 N·m (11 ft. lbs.) in the sequence shown (Fig.
122).
(12) Install the engine.

FLEXPLATE
REMOVAL
(1) Remove the transmission. Refer to Group 21,
Transmission and Transfer Case for procedure.
(2) Remove the bolts and flexplate.

Fig. 119 Cutting Aplicator to Achieve 2.5mm (0.100 INSTALLATION

in.) Bead (1) Position the flexplate onto the crankshaft and
1 – CUT HERE install the bolts hand tight.
(2) Tighten the flexplate retaining bolts to 60 N·m
(45 ft. lbs.) in the sequence shown (Fig. 123).
(3) Install the transmission.

OIL PUMP
REMOVAL
(1) Remove the oil pan and pick-up tube. Refer to
the procedure in this section.
(2) Remove the timing chain cover. Refer to the
procedure in this section.
(3) Remove the timing chains and tensioners.
Refer to Timing Chain and Sprockets in this section.
Fig. 120 Cylinder Block-to-Bedplate Sealent Bead (4) Remove the four bolts, primary timing chain
Location tensioner and the oil pump.
1 – CYLINDER BLOCK
2 – SEALANT BEAD LOCATION INSTALLATION
(1) Position the oil pump onto the crankshaft and
(6) Coat the crankshaft main bearing journals install two oil pump retaining bolts.
with clean engine oil and position the bedplate onto (2) Position the primary timing chain tensioner
the cylinder block. and install the two retaining bolts.
(3) Tighten the oil pump and primary timing chain
NOTE: Lubricate the bedplate retaining bolts with tensioner retaining bolts to 28 N·m (250 in. lbs.) in
clean engine oil prior to installation. the sequence shown (Fig. 124).
(4) Install the secondary timing chain tensioners
(7) Install the bedplate retaining bolts, making and timing chains.
sure to place the stud bolts in the correct location, (5) Install the timing chain cover.
Torque the bolts in the sequence shown (Fig. 121). (6) Install the pick-up tube and oil pan.
• Tighten bolts A – L to 54 N·m (40 ft. lbs.)
• Tighten bolts 1–10 to 2.8 N·m (25 in. lbs.)
• Turn bolts 1–10 an additional 90°.

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 9 - 70 4.7L ENGINE DN
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. 125).
(5) Remove the pressure sender (Fig. 125). Fig. 123 Flexplate Tightening Sequence
1 – FLEXPLATE
INSTALLATION
(1) Install oil pressure sender.
(2) Connect oil pressure sender wire. CRANKSHAFT OIL SEAL—FRONT
(3) Install front splash shield.
(4) Lower vehicle. REMOVAL
(5) Connect the negative battery cable. (1) Disconnect negative cable from battery.

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 DN 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. 126).
(7) Remove fan and viscous assembly.

Fig. 124 Oil Pump and Primary Timing Chain

Tightening Sequence

Fig. 126 Fan Assembly—Removal/Installation

1 – SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2 – FAN

(8) Disconnect electrical connector for fan mounted

inside radiator shroud.
(9) Remove radiator shroud attaching fasteners.

NOTE: Transmission cooler line snaps into shroud

lower right hand corner.

(10) Remove radiator shroud.

(11) Remove crankshaft damper bolt.
(12) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 127).
(13) Using Special Tool 8511, remove crankshaft
front seal (Fig. 128).
Fig. 125 Oil Pressure Sending Unit
1 – BELT
2 – OIL PRESSURE SENSOR
INSTALLATION
3 – OIL FILTER
4 – ELEC. CONNECTOR
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
(2) Remove accessory drive belt refer to Group 7, before installing Damper.
Cooling System for procedure.
(3) Remove A/C compressor mouning fasteners and (1) Using Special Tool 8348 and 8512, install
set aside. crankshaft front seal (Fig. 129).

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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. Then the roller bear-
ing is placed onto the threaded rod (The hardened
bearing surface of the bearing MUST face the nut).
Then the hardened washer slides onto the threaded
rod (Fig. 130). Once assembled coat the threaded
rod’s threads with Mopart Nickel Anti-Seize or (Loc-
tite No. 771).
(3) Align crankshaft damper slot with key in
crankshaft. Slide damper onto crankshaft slightly.
(4) Using Special Tool 8512 press damper onto
crankshaft (Fig. 131).
(5) Install then tighten crankshaft damper bolt to
175 N·m (130 ft. lbs.).
(6) Install radiator shroud and tighten fasteners to
11 N·m (95 in. lbs.).
(7) Connect electrical connector for shroud fan.
(8) Install fan and viscous assembly.
(9) Using Special Tools 6958 Spanner with Adapter
Pins 8346 tighten fan and viscous assembly to water
pump (Fig. 126).
Fig. 128 Crankshaft Front Seal—Removal (10) Install upper radiator hose.
1 – SPECIAL TOOL 8511 (11) Install A/C compressor and tighten fasteners
to 54 N·m (40 ft. lbs.).
CAUTION: Special Tool 8512, is assembled in a (12) Install accessory drive belt refer to Group 7,
specific sequence. Failure to assemble this tool in Cooling System for procedure.
this sequence can result in tool failure and severe (13) Refill cooling system. Refer to Group 7, Cool-
damage to either the tool or the crankshaft. ing System for procedure.
(14) Connect negative cable to battery.

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 DN 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.

NOTE: The crankshaft rear oil seal remover Special

Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.

Fig. 130 Proper Assembly Method for Special Tool (3) Using Special Tool 8506 (Fig. 132), remove the
8512 crankshaft rear oil seal.
1 – BEARING
2 – NUT
3 – THREADED ROD
4 – BEARING HARDENED SURFACE (FACING NUT)
5 – HARDENED WASHER

Fig. 132 Crankshaft Rear Oil Seal Removal

1 – REAR CRANKSHAFT SEAL
2 – SPECIAL TOOL 8506

INSTALLATION
(1) Position the magnetic seal guide Special Tool
8349–2 (Fig. 133) onto the crankshaft rear face. Then
position the crankshaft rear oil seal onto the guide.
Fig. 131 Crankshaft Damper—Installation (2) Using Special Tools 8349 Crankshaft Rear Oil
1 – SPECIAL TOOL 8512 Seal Installer and C-4171 Driver Handle (Fig. 134),
with a hammer, tap the seal into place. Continue to
tap on the driver handle until the seal installer seats
CRANKSHAFT OIL SEAL—REAR against the cylinder block crankshaft bore.
(3) Install the flexplate.
REMOVAL (4) If removed, install the transmission.
NOTE: This procedure can be preformed in vehicle.

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 9 - 74 4.7L ENGINE DN
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 – DRIFT PUNCH
1 – REAR CRANKSHAFT SEAL 5 – CUP PLUG
2 – SPECIAL TOOL 8349–2 GUIDE

(3) Using a suitable pair of pliers, grasp the core

plug and remove.

INSTALLATION
NOTE: Thoroughly clean core plug bore, remove all
of the old sealer.

(1) Coat the edges of the engine core plug and the
core plug bore with Mopar Gasket Maker, or equiva-
lent.

NOTE: It is not necessary to wait for the sealant to

cure on the core plugs. The cooling system can be
filled and the vehicle returned to service immedi-
ately.

(2) Using proper plug driver, drive core plug into

the core plug bore. The sharp edge of the core plug
should be at least 0.50 mm (0.020 in.) inside the lead
Fig. 134 Crankshaft Rear Oil Seal Installation in chamfer.
1 – REAR CRANKSHAFT SEAL
(3) Refill the cooling system.
2 – SPECIAL TOOL 8349–1 INSTALLER
3 – SPECIAL TOOL C-4171 HANDLE
DISASSEMBLY AND ASSEMBLY
ENGINE CORE PLUGS OIL PUMP
REMOVAL DISASSEMBLE
(1) Drain the cooling system. Refer to Group 7, (1) Remove oil pump cover screws and lift off cover
Cooling System for procedure. plate.
(2) Using a blunt tool such as a drift or a screw (2) Remove pump inner and outer rotors.
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 135).

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 DN 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
replaced. would prevent sealing.

(3) If it is necessary to remove the pressure relief CYLINDER HEADS

valve, drive the roll pin from pump housing and
remove cup plug, spring and valve. CLEANING
ASSEMBLE CYLINDER HEAD GASKET SURFACE PREPARATION
(1) Wash all parts in a suitable solvent and inspect To ensure engine gasket sealing, proper surface
carefully for damage or wear. preparation must be performed, especially with the
(2) Install inner and outer rotors use of aluminum engine components.
(3) Install oil pump cover plate and install cover Never use the following to clean gasket surfaces:
bolts and tighten them to 12 N·m (105 in. lbs.). • never use a metal scraper.
(4) Prime oil pump before installation by filling • never use an abrasive pad or paper to
rotor cavity with engine oil. clean the cylinder block.
(5) If oil pressure is low and pump is within spec- • never use a high speed power tool or wire
ifications, inspect for worn engine bearings or other brush on any gasket sealing surface (Fig. 136).
causes for oil pressure loss. Only use the following for cleaning gasket surfaces:
• use Mopart Brake and Parts Cleaner
• use only a plastic or wood scraper (Fig. 136)
CLEANING AND INSPECTION
INTAKE MANIFOLD
CLEANING
NOTE: There is NO approved repair procedure for
the intake manifold. If severe damage is found dur-
ing inspection, the intake manifold must be
replaced.

Before installing the intake manifold thoroughly

clean the mating surfaces. Use a suitable cleaning
solvent, then air dry.

INSPECTION
(1) Inspect the intake sealing surface for cracks,
nicks and distortion.
(2) Inspect the intake manifold vacuum hose fit-
tings for looseness or blockage.
(3) Inspect the manifold to throttle body mating
surface for cracks, nicks and distortion.
Fig. 136 Proper Tool Usage For Surface Preparation
EXHAUST MANIFOLD 1 – PLASTIC/WOOD SCRAPER

CLEANING
(1) Clean the exhaust manifold using a suitable
INSPECTION
(1) Inspect the cylinder head for out-of-flatness,
cleaning solvent, then allow to air dry.
using a straightedge and a feeler gauge. If tolerances
(2) Clean all gasket residue from the manifold
exceed 0.0508 mm (0.002 in.) replace the cylinder
mating surface.
head.
INSPECTION (2) Inspect the valve seats for damage. Service the
valve seats as necessary.
(1) Inspect the exhaust manifold for cracks in the
(3) Inspect the valve guides for wear, cracks or
mating surface and at every mounting bolt hole.
looseness. If either condition exist, replace the cylin-
(2) Using a straight edge and a feeler gauge, check
der head.
the mating surface for warp and twist.

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 9 - 76 4.7L ENGINE DN
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
CLEANING cover is scratched or grooved the oil pump assembly
should be replaced.
CAUTION: DO NOT use a wire wheel or other abra- (2) Lay a straight edge across the pump cover sur-
sive cleaning devise to clean the pistons or con- face (Fig. 137). If a 0.025 mm (0.001 in.) feeler gauge
necting rods. The pistons have a Moly coating, this can be inserted between the cover and the straight
coating must not be damaged. edge the oil pump assembly should be replaced.
(3) Measure the thickness of the outer rotor (Fig.
(1) Using a suitable cleaning solvent clean the pis- 138). If the outer rotor thickness measures at 12.005
tons in warm water and towel dry. mm (0.400 in.) or less the oil pump assembly must be
(2) Use a wood or plastic scraper to clean the ring replaced.
land grooves. (4) Measure the diameter of the outer rotor. If the
outer rotor diameter measures at 85.925 mm (0.400
CAUTION: DO NOT remove the piston pin from the in.) or less the oil pump assembly must be replaced.
piston and connecting rod assembly. (5) Measure the thickness of the inner rotor (Fig.
139). If the inner rotor thickness measures at 12.005
mm (0.400 in.) or less then the oil pump assembly
INSPECTION must be replaced.
Check the crankshaft connecting rod journal for (6) Slide outer rotor into the body of the oil pump.
excessive wear, taper and scoring. Press the outer rotor to one side of the oil pump body
Check the pistons for taper and elliptical shape and measure clearance between the outer rotor and
before they are fitted into the cylinder bore. the body (Fig. 140). If the measurement is 0.47mm
Replace any piston and connecting rod not meeting (0.0186 in.) or more the oil pump assembly must be
the specifications. replaced.
(7) Install the inner rotor in the into the oil pump
OIL PAN body. Measure the clearance between the inner and
outer rotors (Fig. 141). If the clearance between the
CLEANING rotors is .150 mm (0.006 in.) or more the oil pump
(1) Clean oil pan in solvent and wipe dry with a assembly must be replaced.
clean cloth. (8) Place a straight edge across the body of the oil
(2) Clean the oil pan gasket surface. DO NOT use pump (between the bolt holes), if a feeler gauge of
a grinder wheel or other abrasive tool to clean seal- .095 mm (0.0038 in.) or greater can be inserted
ing surface. between the straightedge and the rotors, the pump
(3) Clean oil screen and tube thoroughly in clean must be replaced (Fig. 142).
solvent.
NOTE: 4.7 Oil pump is released as an assembly.
INSPECTION There are no DaimlerChrysler part numbers for Sub-
(1) Inspect oil drain plug and plug hole for Assembly components. In the event the oil pump is
stripped or damaged threads. Repair as necessary. not functioning or out of specification it must be
(2) Inspect the oil pan mounting flange for bends replaced as an assembly.
or distortion. Straighten flange, if necessary.

OIL PUMP CYLINDER BLOCK

CLEANING CLEANING
(1) Wash all parts in a suitable solvent. Thoroughly clean the oil pan and engine block gas-
ket surfaces.
INSPECTION Use compressed air to clean out:
• The galley at the oil filter adaptor hole.
CAUTION: Oil pump pressure relief valve and • The front and rear oil galley holes.
spring should not be removed from the oil pump. If • The feed holes for the crankshaft main bearings.
the these components are disassembled andør Once the block has been completely cleaned, apply
removed from the pump the entire oil pump assem- Loctite PST pipe sealant with Teflon 592 to the
bly must be replaced. threads of the front and rear oil galley plugs. Tighten
the plugs to 34 N·m (25 ft. lbs.) torque.

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 DN 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 – OUTER ROTOR

Fig. 138 Measuring Outer Rotor Thickness

Fig. 141 Measuring Clearance Between Rotors

1 – OUTER ROTOR
2 – FEELER GAUGE
3 – INNER ROTOR

INSPECTION
(1) It is mandatory to use a dial bore gauge to
measure each cylinder bore diameter. To correctly
select the proper size piston, a cylinder bore gauge,
capable of reading in 0.003 mm (.0001 in.) INCRE-
Fig. 139 Measuring Inner Rotor Thickness
MENTS is required. If a bore gauge is not available,
do not use an inside micrometer (Fig. 143).

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 9 - 78 4.7L ENGINE DN
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
be honed. If the cylinder bore taper or out- of-round
condition exceeds these maximum limits, the cylinder
block must be replaced. A slight amount of taper
always exists in the cylinder bore after the engine
has been in use for a period of time.

Fig. 142 Measuring Clearance Over Rotors SPECIFICATIONS

1 – STRAIGHT EDGE
2 – FEELER GAUGE 4.7L ENGINE

DESCRIPTION SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type 90° SOHC V-8 16-Valve
Displacement 4.7 Liters / 4701cc
(287 Cubic Inches)
Bore 93.0 mm (3.66 in.)
Stroke 86.5 mm (3.40 in.)
Compression Ratio 9.0:1
Horsepower 235 BHP @ 4800 RPM
Torque 295 LB-FT @ 3200 RPM
Lead Cylinder #1 Left Bank
Firing Order 1-8-4-3-6-5-7-2
CYLINDER BLOCK
Cylinder Block Cast Iron
Bore Diameter 93.010 6.0075 mm
(3.6619 6 0.0003 in.)
Out of Round (MAX) 0.076 mm (0.003 in.)
Fig. 143 Bore Gauge—Typical
1 – FRONT Taper (MAX) 0.051 mm (0.002 in.)
2 – BORE GAUGE
PISTONS
3 – CYLINDER BORE
4 – 49.5 MM Material Aluminum Alloy
(1–15/16 in)
Diameter 92.975 mm (3.6605 in.)
Weight 367.5 grams (12.96 oz)
(2) Measure the inside diameter of the cylinder
bore at three levels below top of bore. Start perpen- Ring Groove Diameter
dicular (across or at 90 degrees) to the axis of the No. 1 83.73 - 83.97 mm
crankshaft and then take two additional reading.
(3.296 - 3.269 in.)
(3) Measure the cylinder bore diameter crosswise
to the cylinder block near the top of the bore. Repeat No. 2 82.833 - 83.033 mm
the measurement near the middle of the bore, then (3.261 - 3.310 in.)
repeat the measurement near the bottom of the bore.

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 DN 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
(3.302 - 3.310 in.) Round
(MAX) (0.0002 in.)
PISTON PINS
Total Weight (Less 578 grams (20.388
Type Pressed Fit
Bearing) ounces)
Clearance In Piston 0.010 - 0.019 mm
CRANKSHAFT
(0.0004 - 0.0008 in.)
Main BearingJournal
Diameter 24.013 - 24.016 mm
Diameter 63.488 - 63.512 mm
(0.9454 - 0.9456 in.)
(2.4996 - 2.5005 in.)
PISTON RINGS
Bearing Clearance 0.004 - 0.032 mm
Ring Gap
(0.0002 - 0.0013 in.)
Top Compression Ring 0.37 - 0.63 mm
Out of Round (MAX) 0.005 mm (0.0002 in.)
(0.0146 - 0.0249 in.)
Taper (MAX) 0.008 mm (0.0004 in.)
Second Compression 0.37 - 0.63 mm End Play 0.052 - 0.282 mm
Ring
(0.0021 - 0.0112 in.)
(0.0146 - 0.0249 in.)
End Play (MAX) 0.282 mm (0.0112 in)
Oil Control (Steel Rails) 0.25 - 0.76 mm
Connecting Rod
(0.0099 - 0.30 in.) Journal
Side Clearance Diameter 50.992 - 51.008 mm
Top Compression Ring .051 -.094 mm (2.0076 - 2.0082 in.)
(0.0020 - 0.0037 in.) Bearing Clearance 0.010 - 0.048 mm
Second Compression 0.040 - 0.080 mm (0.0004 -0.0019 in.)
Ring
Out of Round (MAX) 0.005 mm (0.0002 in.)
(0.0016 - 0.0031 in.) Taper (MAX) 0.008 mm (0.0004 in.)
Oil Ring (Steel Ring) .019 -.229 mm
CAMSHAFT
(.0007 -.0091 in.) Bore Diameter 26.02 - 26.04 mm
Ring Width (1.0245 - 1.0252 in.)
Top Compression Ring 1.472 - 1.490 mm Bearing Journal Diameter 25.975 - 25.995 mm
(0.057 - 0.058 in.) (1.0227 - 1.0235 in.)
Second Compression 1.472 - 1.490 mm Bearing Clearance 0.025 - 0.065 mm
Ring
(0.001 - 0.0026 in.)
(0.057 - 0.058 in.) Bearing Clearance (MAX) 0.065 mm (0.0026 in.)
Oil Ring (Steel Rails) 0.445 - 0.470 mm End Play .075 -.200 mm
(0.017 - 0.018 in.) (0.003 - 0.0079 in.)
CONNECTING RODS End Play (MAX) .200 mm (0.0079 in.)
Bearing Clearance 0.010 - 0.048 mm VALVE TIMING
(0.0004 - 0.0019 in.) Intake
Side Clearance 0.10 - 0.35 mm
Opens (ATDC) 3.6°
(0.004 - 0.0138 in.)
Closes (ATDC) 247.1°
Piston Pin Bore Diameter .022 -.045 mm
Duration 243.5°
(Interference Fit) (0.0009 - 0.0018 in.)

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 9 - 80 4.7L ENGINE DN
2000 DN Service Manual
SPECIFICATIONS (Continued) Publication No. 81-370-0016
TSB 26-12-99 December, 1999

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Exhaust Spring Force (Valve
Opens (BTDC) 232.5° Closed)
Closes (ATDC) 21.2° Intake and Exhaust 315.5 - 352.5 N @ 40.89
mm
Duration 253.70°
Valve Overlap 17.6° (70.92722 - 79.24515 lbs.
@ 1.6099 in.)
VALVES
Spring Force (Valve
Face Angle 45° - 45.5° Open)
Head Diameter Intake and Exhaust 786.0 - 860.0 N @ 29.64
Intake 48.52 - 48.78 mm mm
(1.9103 - 1.9205 in.) 176.6998 - 193.3357 lbs.
@ 1.167 in.)
Exhaust 36.87 - 37.13 mm
1.4516 - 1.4618 in.) Number of Coils
Intake and Exhaust 6.69
Length (Overall)
Intake 113.45 - 114.21 mm Wire Diameter

(4.4666 - 4.4965) Intake and Exhaust 4.2799 - 4.3561 mm

Exhaust 114.92 - 115.68 mm (0.1685 - 0.1715 in.)

Installed Height
(4.5244 - 4.5543 in.)
(Top of Valve Stem Seal
Stem Diameter to Bottom of Retainer)
Intake 6.931 - 6.957 mm Nominal
(0.2729 - 0.2739 in.) Early Build
Exhaust 6.902 - 6.928 mm Intake 40.97 mm (1.613 in.)
(0.2717 - 0.2728 in.) Exhaust 40.81 mm (1.606 in.)
Stem - to - Guide Late Build
Clearance Intake 40.11 mm (1.5792 in.)
Intake .018 -.069 mm Exhaust 40.13 mm (1.58 in.)
(0.0008 - 0.0028 in.) CYLINDER HEAD
Exhaust .047 -.098 mm Gasket Thickness
(0.0019 - 0.0039 in.) (Compressed) .7 mm (0.0276 in.)
Max. Allowable Stem - Valve Seat Angle 44.5° - 45.0°
to -
Valve Seat Runout (MAX) 0.051 mm (0.002 in.)
Guide Clearance
Valve Seat Width
(Rocking Method)
Intake 1.75 - 2.36 mm
Intake 0.069 mm (0.0028 in.)
(0.0698 - 0.0928 in.)
Exhaust 0.098 mm (0.0039 in.)
Exhaust 1.71 - 2.32 mm
Valve Lift (Zero Lash)
(0.0673 - 0.0911 in.)
Intake 11.25 mm (0.443 in.)
Guide Bore Diameter (Std.) 6.975 - 7.00 mm
Exhaust 10.90 mm (0.4292 in.)
(0.2747 - 0.2756 in.)
VALVE SPRING Cylinder Head Warpage
Free Lenght (Approx) (Flatness) 0.0508 mm (0.002 in.)
Intake and Exhaust 48.6 mm (1.9134 in.)

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 DN 4.7L ENGINE 9 - 81
SPECIFICATIONS (Continued)

DESCRIPTION SPECIFICATION DESCRIPTION N·m Ft. In.

OIL PUMP Lbs. Lbs.
Clearance Over Rotors .035 -.095 mm Flexplate—Bolts 60 45 —
(MAX) Engine Mount Bracket to 61 45 —
(0.0014 - 0.0038 in.) Block—Bolts
Cover Out - of -Flat .025 mm (0.001 in.) Rear Mount to 46 34 —
(MAX) Transmission—Bolts
Inner and Outer Rotor Generator Mounting—Bolts
Thickness 12.08 mm (0.4756 in.) M10 Bolts 54 40 —
Outer Rotor Clearance 85.96 mm (3.3843 in.) M8 Bolts 28 — 250
(MAX) Intake Manifold—Bolts 12 — 105
Outer Rotor Diameter 85.925 mm (0.400 in.)
Refer to Procedure
(MIN)
for
Tip Clearance Between
Tightening Sequence
Rotors
Oil Pan—Bolts 15 — 130
(MAX) .150 mm (0.006 in.)
Oil Pan—Drain Plug 34 25 —
OIL PRESSURE
Oil Pump—Bolts 28 — 250
At Curb Idle Speed 25 kPa (4 psi)
Oil Pump Cover—Bolts 12 — 105
(MIN)*
Oil Pickup Tube—Bolt and 28 — 250
@ 3000 rpm 170 - 550 kPa (25 - 80
Nut
psi)
Oil Dipstick Tube—Bolt 28 — 250
* CAUTION: If pressure is zero at curb idle, DO
NOT run engine at 3000 rpm. Oil Fill Tube—Bolts 12 — 105
Timing Chain Guide—Bolts 28 — 250
TORQUE Timing Chain Tensioner
Arm—Special
DESCRIPTION N·m Ft. In. Pin Bolt 17 — 150

Lbs. Lbs. Hydraulic Tensioner—Bolts 28 — 250

Camshaft Timing Chain Primary 28 — 250

Tensioner—Bolts
Non - Oiled Sprocket Bolt 122 90 —
Timing Drive Idler Sprocket— 34 25 —
Bearing Cap Bolts 11 — 100 Bolt
Timing Chain Cover—Bolts 54 40 — Thermostat Housing—Bolts 12 — 105
Connecting Rod Cap—Bolts 27 20 — Water Pump—Bolts 54 40 —
PLUS 90° TURN
Bed Plate—Bolts Refer to Procedure
Crankshaft Damper—Bolt 175 130 —
Cylinder Head—Bolts
M11 Bolts 81 60 —
M8 Bolts 28 — 250
Cylinder Head Cover—Bolts 12 — 105
Exhaust Manifold—Bolts 25 18 —
Exhaust Manifold Heat 8 — 72
Shield—Nuts
Then loosen 45°

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 9 - 82 4.7L ENGINE DN

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

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 DN 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

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 9 - 84 4.7L ENGINE DN
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

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 DN 4.7L ENGINE 9 - 85
SPECIAL TOOLS (Continued)

Pressure Tester Kit 7700

Piston Ring Compressor C-385

Bloc–Chek–Kit C-3685–A

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 9 - 86 5.2L ENGINE DN

5.2L ENGINE

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 107

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 108
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . 87 HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 109
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 89 VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . 109
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 89 TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . 110
CYLINDER HEAD COVER GASKET . . . . . . . . . . . 90 TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 111
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 90 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . 90 CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . 113
ENGINE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . 90 CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 113
CRANKSHAFT OIL SEALS . . . . . . . . . . . . . . . . . . 90 DISTRIBUTOR DRIVE SHAFT BUSHING . . . . . . 114
PISTON AND CONNECTING ROD . . . . . . . . . . . . 90 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . . 91 PISTON AND CONNECTING ROD ASSEMBLY . . 116
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 116
SERVICE PROCEDURES OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
FORM-IN-PLACE GASKETS. . . . . . . . . . . . . . . . . 91 CRANKSHAFT OIL SEAL—FRONT . . . . . . . . . . . 117
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . . 92 CRANKSHAFT OIL SEALS—REAR . . . . . . . . . . . 118
ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 ENGINE CORE OIL AND CAMSHAFT PLUGS . . 120
REPAIR DAMAGED OR WORN THREADS . . . . . . 94 DISASSEMBLY AND ASSEMBLY
CYLINDER BORE—HONING . . . . . . . . . . . . . . . . 94 VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 121
HYDROSTATIC LOCK . . . . . . . . . . . . . . . . . . . . . 95 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . 124
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 95 CLEANING AND INSPECTION
MEASURING TIMING CHAIN STRETCH. . . . . . . . 97 CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 124
PISTONS—FITTING . . . . . . . . . . . . . . . . . . . . . . . 98 CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . 124
PISTON RINGS—FITTING . . . . . . . . . . . . . . . . . . 98 PISTON AND CONNECTING ROD ASSEMBLY . . 124
CONNECTING ROD BEARINGS—FITTING. . . . . 100 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
CRANKSHAFT MAIN BEARINGS—FITTING . . . . 100 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
REMOVAL AND INSTALLATION CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . 127
ENGINE MOUNTS—FRONT . . . . . . . . . . . . . . . . 100 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 127
ENGINE MOUNT—REAR . . . . . . . . . . . . . . . . . . 102 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 127
ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . 102 SPECIFICATIONS
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 103 5.2L ENGINE SPECIFICATIONS . . . . . . . . . . . . . 128
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 105 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 132
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 106 SPECIAL TOOLS
ROCKER ARMS AND PUSH RODS . . . . . . . . . . 107 5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE . . . . . . . . . . . . . 107

DESCRIPTION AND OPERATION The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
ENGINE bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1). This
engine is designed for unleaded fuel.
DESCRIPTION The engine serial number is stamped into a
The 5.2 Liter (318 CID) eight-cylinder engine is a machined pad located on the left, front corner of the
V-Type lightweight, single cam, overhead valve cylinder block. When component part replacement is
engine with hydraulic roller tappets. necessary, use the engine type and serial number for
The engine lubrication system consists of a rotor reference (Fig. 2).
type oil pump and a full flow oil filter.

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 DN 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 – SPRING
7 – RELIEF VALVE
8 – LARGE CHAMFERED EDGE
9 – BOLT
10 – COVER
11 – OUTER ROTOR

ing, back up to the left side of the block, and into the
oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
Fig. 2 Engine Identification Number hole lines up, oil is then thrown off as the rod
rotates. This oil throwoff lubricates the camshaft
ENGINE LUBRICATION SYSTEM lobes, distributor drive gear, cylinder walls, and pis-
ton pins.
DESCRIPTION The hydraulic valve tappets receive oil directly
A gear-type positive displacement pump (Fig. 3) is from the main oil gallery. The camshaft bearings
mounted at the underside of the rear main bearing receive oil from the main bearing galleries. The front
cap. The pump uses a pick-up tube and screen camshaft bearing journal passes oil through the cam-
assembly to gather engine oil from the oil pan. shaft sprocket to the timing chain. Oil drains back to
the oil pan under the No. 1 main bearing cap.
OPERATION The oil supply for the rocker arms and bridged
The pump draws oil through the screen and inlet pivot assemblies is provided by the hydraulic valve
tube from the sump at the rear of the oil pan. The oil tappets, which pass oil through hollow push rods to a
is driven between the drive and idler gears and hole in the corresponding rocker arm. Oil from the
pump body, then forced through the outlet to the rocker arm lubricates the valve train components.
block. An oil gallery in the block channels the oil to The oil then passes down through the push rod guide
the inlet side of the full flow oil filter. After passing holes and the oil drain-back passages in the cylinder
through the filter element, the oil passes from the head, past the valve tappet area, and then returns to
center outlet of the filter through an oil gallery that the oil pan.
channels the oil up to the main gallery, which
extends the entire length on the right side of the
block. The oil then goes down to the No. 1 main bear-

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 9 - 88 5.2L ENGINE DN
DESCRIPTION AND OPERATION (Continued)

Fig. 4 Oil Lubrication System

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 DN 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 – DRIP OILING FOR VALVE TIP 18 –
OIL TO FILTER
6 – CYLINDER HEAD BOSS 19 –
OIL FROM FILTER TO SYSTEM
7 – TO MAIN BEARINGS 20 –
PASSAGE TO CAMSHAFT REAR BEARING
8 – TO CAMSHAFT BEARINGS 21 –
RIGHT OIL GALLERY
9 – ROCKER ARM 22 –
PLUG
10 – HOLLOW PUSH ROD 23 –
OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT
11 – TAPPET 24 –
OIL SUPPLY VIA HOLLOW PUSH ROD SUPPLY IS FROM
12 – TO CONNECTING ROD BEARINGS OIL GALLERY METERED THROUGH HYDRAULIC TAPPET
13 – OIL INTAKE 25 – OIL SUPPLY FROM HOLLOW PUSH ROD

EXHAUST MANIFOLD must be used when sealing the gaskets to ensure

that excess sealant does not enter the intake runners
DESCRIPTION causing a restriction. Whenever the intake manifold
The exhaust manifolds are constructed of cast iron is removed inspect the plenum pan for evidence of
and are LOG type with balanced flow (Fig. 5). One excess oil buildup, this condition indicates that the
exhaust manifold is attached to each cylinder head. plenum pan gasket is leaking.

Fig. 5 Exhaust Manifolds—V-8 Gas Engines Typical

1 – EXHAUST MANIFOLD (LEFT)
2 – BOLTS & WASHERS
3 – NUTS & WASHERS
4 – EXHAUST MANIFOLD (RIGHT)
5 – BOLTS & WASHERS Fig. 6 Intake Manifold and Throttle Body—V-8 Gas
Engines Typical
1 – FUEL RAIL ASSEMBLY
OPERATION 2 – FUEL RAIL MOUNTING BOLTS
The exhaust manifolds collect the engine exhaust 3 – FUEL RAIL CONNECTING HOSES
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipes attached to the
manifolds. OPERATION
The intake manifold, meters and delivers air to the
INTAKE MANIFOLD combustion chambers allowing the fuel delivered by
the fuel injectors to ignite, thus producing power.
DESCRIPTION
The aluminum intake manifold (Fig. 6) is a single
plane design with equal length runners and uses a
separate plenum, therefore the manifold does have a
plenum gasket. It also uses separate flange gaskets
and front and rear cross-over gaskets. Extreme care

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 9 - 90 5.2L ENGINE DN
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
The cylinder head cover gasket is a steel-backed to the correct ratio for ignition. The valves located in
silicone gasket, designed for long life usage (Fig. 7). the cylinder head open and close to either allow clean
air into the combustion chamber or to allow the
exhaust gases out, depending on the stroke of the
engine.

VALVES AND VALVE SPRINGS

DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 48.768 mm (1.92 inches) in
diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch)
Fig. 7 Cylinder Head Cover Gasket V-8 Gas Engines wafer interia welded to the tip for durability. These
1 – CYLINDER HEAD COVER GASKET valves are not splayed.

OPERATION ENGINE OIL PAN

The steel-backed silicone gasket is designed to seal
the cylinder head cover for long periods of time
DESCRIPTION
The stamped steel engine oil pan is located at the
through extensive heat and cold, without failure. The
bottom of the engine, and contains a drain plug for
gasket is designed to be reusable.
draining the engine oil.
CYLINDER HEAD OPERATION
The oil pan holds the engine oil and seals and pro-
DESCRIPTION
tects the engine lower components from contami-
The cast iron cylinder heads are mounted to the
nates.
cylinder block using ten bolts (Fig. 8). The spark
plugs are located in the peak of the wedge between
the valves.
CRANKSHAFT OIL SEALS
DESCRIPTION
The crankshaft rear seal is a two piece viton seal.
The crankshaft front seal is a one piece viton seal
with a steel housing. The front seal is located in the
engine front cover. One part of the two piece rear
seal is located in a slot in the number five (5) crank-
shaft main bore, the second part of the two piece seal
is located in the number five (5) main bearing cap.

OPERATION
The crankshaft seals prevent oil from leaking from
around the crankshaft, either from the rear of the
engine or from the engine front cover.

Fig. 8 Cylinder Head Assembly—V-8 Gas Engines

PISTON AND CONNECTING ROD
1 – EXHAUST VALVE
2 – SPARK PLUGS
DESCRIPTION
3 – EXHAUST VALVES The pistons are made of aluminum and have three
4 – SPARK PLUGS ring grooves, the top two grooves are for the compres-
5 – EXHAUST VALVE sion rings and the bottom groove is for the oil control
6 – INTAKE VALVES ring. The connecting rods are forged steel and are
7 – INTAKE VALVES coined prior to heat treat. The piston pins are press
fit.

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 DN 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. 9). There
are five main bearings. Number three main bearing
is flanged, this flange controls crankshaft thrust.

Fig. 10 Crankshaft with Journal Size Identification

place gasket material unless specified. Care
must be taken when applying form-in-place gaskets.
Bead size, continuity and location are of great impor-
tance. Too thin a bead can result in leakage while too
much can result in spill-over. A continuous bead of
the proper width is essential to obtain a leak-free
joint.
Two types of form-in-place gasket materials are
Fig. 9 Main Bearing Orientation used in the engine area (Mopar Silicone Rubber
Adhesive Sealant and Mopar Gasket Maker). Each
OPERATION have different properties and cannot be used inter-
The main bearings encircle the crankshaft main changeably.
bearing journals, this aligns the crankshaft to the
centerline of the engine and allows the crankshaft to MOPAR SILICONE RUBBER ADHESIVE SEALANT
turn without wobbling or shaking therefore eliminat- Mopar Silicone Rubber Adhesive Sealant, normally
ing vibration. The main bearings are available in black in color, is available in 3 ounce tubes. Moisture
standard and undersizes. in the air causes the sealant material to cure. This
material is normally used on flexible metal flanges.
CRANKSHAFT It has a shelf life of a year and will not properly cure
if over aged. Always inspect the package for the expi-
DESCRIPTION ration date before use.
The crankshaft is of a cast nodular steel splayed
type design, with five main bearing journals. The MOPAR GASKET MAKER
crankshaft is located at the bottom of the engine Mopar Gasket Maker, normally red in color, is
block and is held in place with five main bearing available in 6 cc tubes. This anaerobic type gasket
caps. The number 3 counterweight is the location for material cures in the absence of air when squeezed
journal size identification (Fig. 10). between smooth machined metallic surfaces. It will
not cure if left in the uncovered tube. DO NOT use
OPERATION on flexible metal flanges.
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or SURFACE PREPARATION
flexplate. Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some
instances, it may be necessary to lightly tap the part
SERVICE PROCEDURES with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
FORM-IN-PLACE GASKETS may also be lightly tapped into the joint but care
There are several places where form-in-place gas- must be taken not to damage the mating surfaces.
kets are used on the engine. DO NOT use form-in-

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 9 - 92 5.2L ENGINE DN
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. Flatten rails with a hammer on emission controls see Group 25, Emission Controls
a flat plate, if required. Gasket surfaces must be free for service procedures.
of oil and dirt. Make sure the old gasket material is (10) Road test vehicle as a final test.
removed from blind attaching holes.
ENGINE OIL
GASKET APPLICATION
Assembling parts using a form-in-place gasket WARNING: NEW OR USED ENGINE OIL CAN BE
requires care. IRRITATING TO THE SKIN. AVOID PROLONGED OR
Mopar Silicone Rubber Adhesive Sealant should be REPEATED SKIN CONTACT WITH ENGINE OIL.
applied in a continuous bead approximately 3 mm CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
(0.12 inch) in diameter. All mounting holes must be INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4 YOUR HEALTH. THOROUGHLY WASH EXPOSED
inch) drop is placed in the center of the gasket con- SKIN WITH SOAP AND WATER. DO NOT WASH
tact area. Uncured sealant may be removed with a SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
shop towel. Components should be torqued in place SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
while the sealant is still wet to the touch (within 10 NOT POLLUTE, DISPOSE OF USED ENGINE OIL
minutes). The use of a locating dowel is recom- PROPERLY.
mended during assembly to prevent smearing the
material off location.
Mopar Gasket Maker should be applied sparingly ENGINE OIL SPECIFICATION
to one gasket surface. The sealant diameter should
CAUTION: Do not use non-detergent or straight
be 1.00 mm (0.04 inch) or less. Be certain the mate-
mineral oil when adding or changing crankcase
rial surrounds each mounting hole. Excess material
lubricant. Engine failure can result.
can easily be wiped off. Components should be
torqued in place within 15 minutes. The use of a
locating dowel is recommended during assembly to API SERVICE GRADE CERTIFIED
prevent smearing the material off location. In gasoline engines, use an engine oil that is API
Service Grade Certified (Fig. 11). Standard engine oil
ENGINE PERFORMANCE identification notations have been adopted to aid in
It is important that the vehicle is operating to its the proper selection of engine oil. The identifying
optimum performance level to maintain fuel economy notations are located on the label of engine oil plastic
and the lowest emission levels. If vehicle is not oper- bottles and the top of engine oil cans. MOPAR only
ating to these standards, refer to Engine Diagnosis provides engine oil that conforms to this certification.
outlined in this section. The following procedures can
assist in achieving the proper engine diagnosis.
(1) Test cranking amperage draw. Refer to Electri-
cal Group 8B, Cold Cranking Test.
(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.
Tighten to specifications.
Fig. 11 Engine Oil Container Standard Notations
(5) Test resistance of spark plug cables. Refer to
Electrical Group 8D, Spark Plug Cables. SAE VISCOSITY
(6) Inspect the primary wires. Test coil output volt- An SAE viscosity grade is used to specify the vis-
age and primary resistance. Replace parts as neces- cosity of engine oil. SAE 10W-30 specifies a multiple
sary. Refer to Electrical Group 8D, for specifications. viscosity engine oil. These are specified with a dual
(7) Test fuel pump for pressure. Refer to Group 14, SAE viscosity grade which indicates the cold-to-hot
Fuel System Specifications. temperature viscosity range. When choosing an
(8) The air filter elements should be replaced as engine oil, consider the range of temperatures the
specified in Lubrication and Maintenance, Group 0. vehicle will be operated in before the next oil change.
Select an engine oil that is best suited to your area’s

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 DN 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.
(1) Position vehicle on level surface.
(2) With engine OFF, allow approximately ten min-
utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Install dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the ADD mark on
dipstick.
Fig. 12 Temperature/Engine Oil Viscosity
Recommendation
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
ENERGY CONSERVING OIL described in the Maintenance Schedule. This infor-
An Energy Conserving type oil is recommended for mation can be found in your owner’s manual.
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con- TO CHANGE ENGINE OIL
tainer. Run engine until achieving normal operating tem-
perature.
OIL LEVEL INDICATOR (DIPSTICK) (1) Position the vehicle on a level surface and turn
The engine oil level indicator is located at the right engine off.
front of the engine, left of the generator on 5.2L (2) Hoist and support vehicle on safety stands.
engines (Fig. 13). Refer to Hoisting and Jacking Recommendations.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(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

Fig. 13 Engine Oil Dipstick Location—5.2L Engines
FILTER SPECIFICATION
1 – CYLINDER HEAD COVER
2 – ENGINE OIL FILL-HOLE CAP All engines are equipped with a high quality full-
3 – DIPSTICK flow, disposable type oil filter. DaimlerChrysler Cor-
4 – ENGINE OIL FILTER poration recommends a Mopar or equivalent oil filter
5 – FILTER BOSS be used.

OIL FILTER REMOVAL

CRANKCASE OIL LEVEL INSPECTION (1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
CAUTION: Do not overfill crankcase with engine oil,
(3) Rotate the oil filter counterclockwise to remove
oil foaming and oil pressure loss can result.
it from the cylinder block oil filter boss (Fig. 14).

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 9 - 94 5.2L ENGINE DN
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.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
Fig. 14 Oil Filter Removal—Typical
for this job. In addition to deglazing, it will reduce
1 – ENGINE OIL FILTER
2 – OIL FILTER WRENCH
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
(4) When filter separates from adapter nipple, tip its.
gasket end upward to minimize oil spill. Remove fil-
ter from vehicle. CAUTION: DO NOT use rigid type hones to remove
(5) With a wiping cloth, clean the gasket sealing cylinder wall glaze.
surface (Fig. 15) of oil and grime.
(2) Deglazing of the cylinder walls may be done if
OIL FILTER INSTALLATION the cylinder bore is straight and round. Use a cylin-
(1) Lightly lubricate oil filter gasket with engine der surfacing hone, Honing Tool C-3501, equipped
oil or chassis grease. with 280 grit stones (C-3501-3810). about 20-60
(2) Thread filter onto adapter nipple. When gasket strokes, depending on the bore condition, will be suf-
makes contact with sealing surface, (Fig. 15) hand ficient to provide a satisfactory surface. Using honing
tighten filter one full turn, do not over tighten. oil C-3501-3880, or a light honing oil, available from
(3) Add oil, verify crankcase oil level and start major oil distributors.
engine. Inspect for oil leaks.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.

(3) Honing should be done by moving the hone up

and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 50° to 60°
for proper seating of rings (Fig. 16).

Fig. 15 Oil Filter Sealing Surface—Typical

1 – SEALING SURFACE
2 – RUBBER GASKET
3 – OIL FILTER

REPAIR DAMAGED OR WORN THREADS

CAUTION: Be sure that the tapped holes maintain
the original center line.
Fig. 16 Cylinder Bore Crosshatch Pattern
Damaged or worn threads can be repaired. Essen-
1 – CROSSHATCH PATTERN
tially, this repair consists of:
2 – INTERSECT ANGLE
• Drilling out worn or damaged threads.

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 DN 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. The number of up and down strokes per Allow spring load to bleed tappet down giving in
minute can be regulated to get the desired 50° to 60° effect a solid tappet.
angle. Faster up and down strokes increase the cross- (3) Install a dial indicator so plunger contacts
hatch angle. valve spring retainer as nearly perpendicular as pos-
(5) After honing, it is necessary that the block be sible. Zero the indicator.
cleaned to remove all traces of abrasive. Use a brush (4) Rotate the crankshaft clockwise (normal run-
to wash parts with a solution of hot water and deter- ning direction) until the valve has lifted 0.863 mm
gent. Dry parts thoroughly. Use a clean, white, lint- (0.034 inch). The timing of the crankshaft should
free cloth to check that the bore is clean. Oil the now read from 10° before top dead center to 2° after
bores after cleaning to prevent rusting. top dead center. Remove spacer.

HYDROSTATIC LOCK CAUTION: DO NOT turn crankshaft any further

When an engine is suspected of hydrostatic lock clockwise as valve spring might bottom and result
(regardless of what caused the problem), follow the in serious damage.
steps below.
If reading is not within specified limits:
(1) Perform the Fuel Pressure Release Procedure
• Check sprocket index marks.
(refer to Group 14, Fuel System).
• Inspect timing chain for wear.
(2) Disconnect the battery negative cable.
• Check accuracy of DC mark on timing indicator.
(3) Inspect air cleaner, induction system and
intake manifold to ensure system is dry and clear of
foreign material. VALVE SERVICE
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure VALVE CLEANING
in the cylinder head. Remove the plugs from the Clean valves thoroughly. Discard burned, warped
engine. and cracked valves.
Remove carbon and varnish deposits from inside of
CAUTION: DO NOT use the starter motor to rotate valve guides with a reliable guide cleaner.
the crankshaft. Severe damage could occur.
VALVE INSPECTION
(5) With all spark plugs removed, rotate the crank- Measure valve stems for wear. If wear exceeds
shaft using a breaker bar and socket. 0.051 mm (0.002 inch), replace the valve.
(6) Identify the fluid in the cylinders (i.e. coolant,
fuel, oil, etc.). VALVE GUIDES
(7) Make sure all fluid has been removed from the Measure valve stem guide clearance as follows:
cylinders. (1) Install Valve Guide Sleeve Tool C-3973 over
(8) Repair engine or components as necessary to valve stem and install valve (Fig. 17). The special
prevent this problem from occurring again. sleeve places the valve at the correct height for
(9) Squirt engine oil into the cylinders to lubricate checking with a dial indicator.
the walls. This will prevent damage on restart.
(10) Install new spark plugs.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N·m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil.
(15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.

VALVE TIMING Fig. 17 Positioning Valve with Tool C-3973

(1) Turn crankshaft until the No.6 exhaust valve is 1 – VALVE
closing and No.6 intake valve is opening. 2 – SPACER TOOL

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 9 - 96 5.2L ENGINE DN
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 – VALVE 1 – CONTACT POINT
2 – SPECIAL TOOL C-3339

VALVE FACE AND VALVE SEAT ANGLE CHART

(3) Move valve to and from the indicator. The total
dial indicator reading should not exceed 0.432 mm
ITEM DESCRIPTION SPECIFICATION
(0.017 inch). Ream the guides for valves with over-
size stems if dial indicator reading is excessive or if A SEAT WIDTH– 1.016 - 1.524 mm
the stems are scuffed or scored. INTAKE (0.040 - 0.060 in.)
Service valves with oversize stems are available as SEAT WIDTH– 1.524 - 2.032 mm
shown below.
EXHAUST (0.060 - 0.080 in.)
REAMER SIZES
B FACE ANGLE

REAMER O/S VALVE GUIDE SIZE (INT. and EXT.) 431⁄4° - 433⁄4°
0.076 mm (0.003 in.) 8.026 - 8.052 mm C SEAT ANGLE

(0.316 - 0.317 in.) (INT. and EXT.) 441⁄4° - 443⁄4°

0.381 mm (0.015 in.) 8.331 - 8.357 mm D CONTACT

(0.328 - 0.329 in.) SURFACE —

Slowly turn reamer by hand and clean guide thor- Inspect the remaining margin after the valves are
oughly before installing new valve. Ream the valve refaced (Fig. 20). Valves with less than 1.190 mm
guides from standard to 0.381 mm (0.015 inch). (0.047 inch) margin should be discarded.
Use a 2 step procedure so the valve guides are VALVE SEATS
reamed true in relation to the valve seat:
CAUTION: DO NOT un-shroud valves during valve
• Step 1—Ream to 0.0763 mm (0.003 inch).
seat refacing (Fig. 21).
• Step 2—Ream to 0.381 mm (0.015 inch).
(1) When refacing valve seats, it is important that
REFACING VALVES AND VALVE SEATS the correct size valve guide pilot be used for reseat-
The intake and exhaust valves have a 43-1/4° to ing stones. A true and complete surface must be
43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle obtained.
(Fig. 19). (2) Measure the concentricity of valve seat using a
VALVES dial indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading.

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 DN 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. As an example the compression length of
the spring to be tested is 1-5/16 inch. Turn table of
Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 inch mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 22). Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
Fig. 20 Intake and Exhaust Valves
are indicated on the table for finer adjustments.
1 – MARGIN
Refer to specifications to obtain specified height and
2 – VALVE SPRING RETAINER LOCK GROOVE
3 – STEM
allowable tensions. Discard the springs that do not
4 – FACE meet specifications.

Fig. 22 Testing Valve Spring for Compressed

Length
Fig. 21 Refacing Valve Seats 1 – TORQUE WRENCH
1 – STONE 2 – VALVE SPRING TESTER
2 – PILOT
3 – VALVE SEAT
4 – SHROUD MEASURING TIMING CHAIN STRETCH
NOTE: To access timing chain Refer to Timing
(3) Inspect the valve seat with Prussian blue to
Chain Cover in Removal and Installation Section.
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue (1) Place a scale next to the timing chain so that
then set valve in place. Rotate the valve with light any movement of the chain may be measured.
pressure. If the blue is transferred to the center of (2) Place a torque wrench and socket over cam-
valve face, contact is satisfactory. If the blue is trans- shaft sprocket attaching bolt. Apply torque in the
ferred to the top edge of valve face, lower valve seat direction of crankshaft rotation to take up slack; 41
with a 15° stone. If the blue is transferred to bottom N·m (30 ft. lbs.) torque with cylinder head installed
edge of valve face raise valve seat with a 60° stone. or 20 N·m (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaft

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 9 - 98 5.2L ENGINE DN
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. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N·m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 23).

Fig. 24 Alignment of Timing Marks

1 – TIMING MARKS

Piston diameter should be measured at the top of

skirt, 90° to piston pin axis. Cylinder bores should be
measured halfway down the cylinder bore and trans-
verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).
Fig. 23 Measuring Timing Chain Wear and Stretch Check the pistons for taper and elliptical shape
1 – TORQUE WRENCH
before they are fitted into the cylinder bore (Fig. 25).
2 – 3.175 MM
(0.125 IN.)

(4) Install a new timing chain, if its movement

exceeds 3.175 mm (1/8 inch).
(5) If chain is not satisfactory, remove camshaft
sprocket attaching bolt and remove timing chain with
crankshaft and camshaft sprockets.
(6) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(7) Place timing chain around both sprockets.
(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(10) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 24). Fig. 25 Piston Measurements
(11) Install the camshaft bolt. Tighten the bolt to 1 – 49.53 mm
(1.95 IN.)
47 N·m (35 ft. lbs.) torque.
(12) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new PISTON RINGS—FITTING
thrust plate and up to 0.254 mm (0.010 inch) with a (1) Measurement of end gaps:
used thrust plate. If not within these limits install a (a) Measure piston ring gap 2 inches from bot-
new thrust plate. tom of cylinder bore. An inverted piston can be
used to push the rings down to ensure positioning
PISTONS—FITTING rings squarely in the cylinder bore before measur-
Piston and cylinder wall must be clean and dry. ing.
Specified clearance between the piston and the cylin- (b) Insert feeler gauge in the gap. The top com-
der wall is 0.013-0.038 mm (0.0005-0.0015 inch) at pression ring gap should be between 0.254-0.508
21°C (70°F). mm (0.010-0.020 inch). The second compression

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 DN 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,
PISTON A DIA = PISTON BORE a stamped letter “O”, an oval depression or the
word TOP (Fig. 26) (Fig. 28).
SIZE DIAMETER DIAMETER (c) Using a ring installer, install the top com-
MIN. MAX. MIN. MAX. pression ring with the chamfer facing up (Fig. 27)
(Fig. 28). An identification mark on the ring is a
mm mm mm mm (in.) drill point, a stamped letter “O”, an oval depression
(in.) (in.) (in.) or the word TOP facing up.
A — — — — (d) Measure side clearance between piston ring
and ring land. Clearance should be 0.074-0.097 mm
B 101.580 101.592 101.605 101.618 (0.0029-0.0038 inch) for the compression rings. The
steel rail oil ring should be free in groove, but
(3.9992) (3.9997) (4.0002) (4.0007) should not exceed 0.246 mm (0.0097 inch) side
clearance.
C 101.592 101.605 101.618 101.630 (e) Pistons with insufficient or excessive side
(3.9997) (4.0002) (4.0007) (4.0012) clearance should be replaced.

D 101.605 101.618 101.630 101.643

(4.0002) (4.0007) (4.0012) (4.0017)

E — — — —

DESCRIPTION SPECIFICATION

PISTON PIN BORE 25.007 - 25.015 mm

(.9845 -.9848 in.)

RING GROOVE
HEIGHT
OIL RAIL 4.033 - 4.058 mm Fig. 26 Second Compression Ring Identification
(Typical)
(.1588 -.1598 in.)
1 – SECOND COMPRESSION RING (BLACK CAST IRON)
COMPRESSION 1.529 - 1.554 mm 2 – CHAMFER
RAIL 3 – TWO DOTS
(.0602 -.0612 in.)

TOTAL FINISHED 470.8 6 2 grams

WEIGHT (16.607 6.0706 ounces)

ring gap should be between 0.508-0.762 mm (0.020-

0.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be prop-
erly filed to the correct dimension. Rings with
excess gaps should not be used.
(2) Install rings and confirm ring side clearance:
(a) Install oil rings being careful not to nick or
scratch the piston. Install the oil control rings Fig. 27 Top Compression Ring Identification
according to instructions in the package. It is not (Typical)
necessary to use a tool to install the upper and 1 – TOP COMPRESSION RING (GRAY IN COLOR)
lower rails. Insert oil rail spacer first, then side 2 – CHAMFER
rails. 3 – ONE DOT
(b) Install the second compression rings using
Installation Tool C-4184. The compression rings
must be installed with the identification mark face

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 9 - 100 5.2L ENGINE DN
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-
size. Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing half. DO
NOT file the rods or bearing caps.

Fig. 28 Compression Ring Chamfer Location CRANKSHAFT MAIN BEARINGS—FITTING

(Typical) Bearing caps are not interchangeable and should
1 – CHAMFER
be marked at removal to ensure correct assembly.
2 – TOP COMPRESSION RING Upper and lower bearing halves are NOT inter-
3 – SECOND COMPRESSION RING changeable. Lower main bearing halves of No.2 and 4
4 – PISTON are interchangeable.
5 – CHAMFER Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT
interchangeable with any other bearing halves in the
engine (Fig. 30). Bearing shells are available in stan-
dard and the following undersizes: 0.25 mm (0.001
inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
Never install an undersize bearing that will reduce
clearance below specifications.

Fig. 29 Proper Ring Installation

1 – OIL RING SPACER GAP
2 – SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 – OIL RING RAIL GAP (BOTTOM)
4 – TOP COMPRESSION RING GAP

CONNECTING ROD BEARINGS—FITTING Fig. 30 Main Bearing Identification

Fit all rods on a bank until completed. DO NOT
alternate from one bank to another, because connect- REMOVAL AND INSTALLATION
ing rods and pistons are not interchangeable from
one bank to another. ENGINE MOUNTS—FRONT
The bearing caps are not interchangeable and
should be marked at removal to ensure correct REMOVAL
assembly. On 4WD vehicles the engine front support brackets
Each bearing cap has a small V-groove across the attach directly to engine block and the axle housing.
parting face. When installing the lower bearing shell, The brackets provide a solid interconnection for these
make certain that the V-groove in the shell is in line units (Fig. 31) (Fig. 32). Engine must be supported
with the V-groove in the cap. This provides lubrica- during any service procedures involving the front
tion of the cylinder wall in the opposite bank. support assemblies.

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 DN 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. Remove starter
wires and starter motor assembly.
(6) Remove insulator to frame through bolt (Fig.
33).
(7) Raise engine slightly.
(8) Remove upper insulator to support bracket
stud nut and insulator to support through bolt.
(9) Remove engine mount insulator (Fig. 31) (Fig.
32).
(10) If engine support bracket is to be removed/re-
placed, remove support bracket to transmission bell
housing bolt(s) and three (3) support bracket to
engine block bolts. Remove support bracket (Fig. 31)
(Fig. 32).

Fig. 32 Left Engine Mount Insulator and Support

Bracket
1 – ENGINE SUPPORT BRACKET
2 – INSULATOR
3 – FRONT AXLE

INSTALLATION—4WD
(1) If engine support brackets were removed,
install them and their fasteners (Fig. 31) (Fig. 32).
Tighten support bracket to block bolts to 41 N·m (30
ft. lbs.). Tighten support bracket to transmission bell-
housing bolt(s) to 88 N·m (65 ft. lbs.).
(2) Install Engine mount insulator and tighten
insulator to support bracket nut to 41 N·m (30 ft.
lbs.). Tighten insulator to support bracket through
bolt nut to 102 N·m (75 ft. lbs.).
(3) Lower engine and install insulator to frame
through bolt and nut (Fig. 33). Tighten nut to 95 N·m
(70 ft. lbs.).
Fig. 31 Right Engine Mount Insulator and Support (4) Install starter motor and mounting bolts.
Bracket Tighten bolts to 68 N·m (50 ft. lbs.).
1 – ENGINE SUPPORT BRACKET (5) Connect starter wires.
2 – INSULATOR (6) Remove engine lifting (support) fixture.
3 – FRONT AXLE
(7) Install front axle assembly. (Refer to Group 3,
Differential and Driveline).
(8) Lower the vehicle.
(9) Connect the negative cable to the battery.

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 9 - 102 5.2L ENGINE DN
REMOVAL AND INSTALLATION (Continued)

Fig. 33 Engine Mount Insulator at Frame

1 – NUT
2 – ENGINE SUPPORT BRACKET
3 – INSULATOR Fig. 34 Rear Mount Insulator
4 – NUT 1 – AUTOMATIC TRANSMISSION
5 – THROUGH BOLT 2 – INSULATOR BRACKET
6 – FRAME 3 – INSULATOR
7 – FRONT AXLE 4 – CROSSMEMBER

ENGINE MOUNT—REAR Install stud nuts and tighten to 28 N·m (250 in. lbs.)
torque.
REMOVAL (4) Remove the transmission jack.
(1) Disconnect the negative cable from the battery. (5) Lower the vehicle.
(2) Raise the vehicle on a hoist. (6) Connect the negative cable to the battery.
(3) Support the transmission with a transmission
jack. ENGINE ASSEMBLY
(4) Remove stud nuts holding the insulator to the
crossmember (Fig. 34). REMOVAL
(5) Raise rear of transmission SLIGHTLY. (1) Scribe hood hinge outlines on hood. Remove the
(6) Remove bolts holding the insulator to the insu- hood.
lator bracket (Fig. 34). Remove the insulator. (2) Disconnect the battery negative cable.
(3) Drain cooling system (refer to Group 7, Cooling
INSTALLATION System for the proper procedure).
(1) If the insulator bracket was removed, install (4) Remove the air cleaner.
the bracket to the transmission (Fig. 34). Tighten the (5) Disconnect the radiator and heater hoses.
bolts to 28 N·m (250 in. lbs.) torque. Remove radiator (refer to Group 7, Cooling System
(2) Install the bolts holding insulator to insulator for the correct procedures).
bracket. Tighten the bolts to 28 N·m (250 in. lbs.) (6) Set fan shroud aside.
torque. (7) Disconnect the vacuum supply lines from the
(3) Lower rear of transmission while aligning the intake manifold.
insulator studs into the mounting support bracket. (8) Remove the distributor cap and wires.

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 DN 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). tery/Starter/Generator Service).
(12) Disconnect the fuel supply line. (13) Connect power steering hoses, if equipped.
(13) Disconnect the starter wires. (14) Connect air conditioning hoses.
(14) Disconnect the oil pressure sending unit wire. (15) Evacuate and charge the air conditioning sys-
(15) Discharge the air conditioning system, if tem, if equipped (refer to Group 24, Heater and Air
equipped (refer to Group 24, Heating and Air Condi- Conditioning for service procedures).
tioning for service procedures). (16) Using a new gasket, install throttle body.
(16) Disconnect the air conditioning hoses. Tighten the throttle body bolts to 23 N·m (200 in.
(17) Disconnect the power steering hoses, if lbs.) torque.
equipped. (17) Connect the accelerator linkage.
(18) Remove starter motor (refer to Group 8B, Bat- (18) Connect the starter wires.
tery/Starter/Generator Service). (19) Connect the oil pressure sending unit wire.
(19) Remove the generator (refer to Group 8B, Bat- (20) Install the distributor cap and wiring.
tery/Starter/Generator Service). (21) Connect the vacuum supply lines to the
(20) Raise and support the vehicle on a hoist. intake manifold.
(21) Disconnect exhaust pipe at manifold. (22) Connect the fuel supply lines.
(22) Refer to Group 21, Transmissions for trans- (23) Install the radiator (refer to Group 7, Cooling
mission removal. System). Connect the radiator hoses and heater
hoses.
CAUTION: DO NOT lift the engine by the intake (24) Install fan shroud in position.
manifold. (25) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure).
(23) Install an engine lifting fixture. (26) Install the air cleaner.
(24) The engine and front driving axle (engine/ax- (27) Install the battery.
le/transmission) are connected through insulators (28) Warm engine and adjust.
and support brackets. Separate the engine as follows: (29) Install hood and line up with the scribe
• LEFT SIDE —Remove 2 bolts attaching marks.
(engine/pinion nose/transmission) bracket to trans- (30) Road test vehicle.
mission bell housing. Remove 2 bracket to pinion
nose adaptor bolts. Separate engine from insulator by INTAKE MANIFOLD
removing upper nut washer assembly and bolt from
engine support bracket. REMOVAL
• RIGHT SIDE —Remove 2 bracket to axle (dis- (1) Disconnect the battery negative cable.
connect housing) bolts and a bracket to bell housing (2) Drain the cooling system. Refer to COOLING
bolt. Separate engine from insulator by removing SYSTEM.
upper nut washer assembly and bolt from engine (3) Remove the A/C compressor. Refer to HEAT-
support bracket. ING and AIR CONDITIONING.
(25) Lower the vehicle. (4) Remove the generator. Refer to CHARGING
(26) Install engine assembly on engine repair SYSTEM.
stand. (5) Remove the accessory drive bracket.
(6) Remove the air cleaner assembly and air inlet
INSTALLATION hose.
(1) Remove engine from the repair stand and posi-
(7) Perform the fuel pressure release procedure.
tion in the engine compartment.
Refer to FUEL SYSTEM.
(2) Install an engine support fixture.
(8) Disconnect the fuel supply line from the fuel
(3) Raise and support the vehicle on a hoist. rail. Refer to FUEL SYSTEM.
(4) Install the engine front mounts.
(9) Disconnect the accelerator linkage and, if so
(5) Refer to Group, 21 Transmissions for transmis-
equipped, the speed control and transmission kick-
sion installation down cables.
(6) Install the inspection plate.
(10) Remove the distributor cap and wires.
(7) Remove transmission support.
(11) Disconnect the coil wires.
(8) Install exhaust pipe to manifold. (12) Disconnect the coolant temperature sending
(9) Lower the vehicle.
unit wire.
(10) Remove engine lifting fixture.

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 9 - 104 5.2L ENGINE DN
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.
(17) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 35). Dis-
card the throttle body gasket.

Fig. 36 Plenum Pan Bolt Tightening Sequence

Fig. 35 Throttle Body Assembly

1 – FUEL RAIL ASSEMBLY
2 – FUEL RAIL MOUNTING BOLTS
3 – FUEL RAIL CONNECTING HOSES

INSTALLATION
(1) If the plenum pan was removed, position pan
gasket and pan.
(2) Install plenum pan retaining bolts. (Fig. 36).
(3) Tighten plenum pan mounting bolts as follows:
• Step 1. Tighten bolts to 5.4 N·m (24 in. lbs.)
• Step 2. Tighten bolts to 9.5 N·m (84 in. lbs.)
• Step 3. Check all bolts are at 9.5 N·m (84 in.
lbs.)
(4) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N·m
(200 in. lbs.) torque.
(5) Apply a bead of Mopar Silicone Rubber Adhe- Fig. 37 Cross-Over Gaskets
sive Sealant, or equivalent, to the four corner joints. 1 – FRONT CROSS-OVER GASKET
The sealant bead height should be slightly higher 2 – REAR CROSS-OVER GASKET
than the cross-over gaskets, approximately 5 mm (0.2
in). An excessive amount of sealant is not required to the block. Also the horizontal alignment tabs must be
ensure a leak proof seal, and an excessive amount of in position with the mating cylinder head gasket tabs
sealant may reduce the effectiveness of the flange (Fig. 38). The words MANIFOLD SIDE should be vis-
gasket. ible on the center of each flange gasket.
(6) Install the front and rear cross-over gaskets (8) Carefully lower intake manifold into position
onto the engine (Fig. 37). on the cylinder block and cylinder heads. long studs
(7) Install the flange gaskets. Ensure that the ver- at the front and rear of the manifold will help to
tical port alignment tab is resting on the deck face of align the intake manifold. After intake manifold is in

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 DN 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. lbs.) torque.
• Step 3—Check that all bolts are tightened to 8
N·m (72 in. lbs.) torque.
• Step 4—Tighten all bolts, in sequence, to 16 N·m
(12 ft. lbs.) torque.
• Step 5—Check that all bolts are tightened to 16
N·m (12 ft. lbs.) torque.
(10) Install closed crankcase ventilation and evap-
oration control systems.
(11) Install the coil wires.
(12) Connect the coolant temperature sending unit
wire.
(13) Connect the heater hoses and bypass hose.
(14) Install distributor cap and wires.
(15) Connect the accelerator linkage and, if so
equipped, the speed control and transmission kick-
down cables.
(16) Install the fuel supply line to the fuel rail.
(17) Install the accessory drive bracket and A/C
compressor.
(18) Install the generator and accessory drive belt.
Tighten generator mounting bolt to 41 N·m (30 ft.
lbs.) torque.
(19) Install the air cleaner assembly and air inlet
Fig. 38 Intake Manifold Flange Gasket Alignment hose.
1 – FLANGE GASKET (20) Fill cooling system.
2 – ALIGNMENT TABS (21) Connect the battery negative cable.
3 – CYLINDER HEAD GASKET

EXHAUST MANIFOLD
place, inspect to make sure seals are in place.
Remove alignment studs if used. REMOVAL
(9) The following torque sequence duplicates the (1) Disconnect the battery negative cable.
expected results of the automated assembly system (2) Raise the vehicle.
(Fig. 39). (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. 40).
(6) Remove two nuts, heat shield and washers
from the left side exhaust manifold, if necessary (Fig.
41).
(7) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(8) Remove manifold from the cylinder head.

INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the exhaust manifold, install new studs.

Fig. 39 Intake Manifold Bolt Tightening Sequence— (1) Position the exhaust manifolds on the two
5.9L Engine studs located on the cylinder head. Install conical
washers and nuts on these studs (Fig. 42).

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 9 - 106 5.2L ENGINE DN
REMOVAL AND INSTALLATION (Continued)

Fig. 42 Exhaust Manifold Installation—5.9L Engine

Fig. 40 Exhaust Manifold Heat Shield—Right Side 1 – EXHAUST MANIFOLD (LEFT)
1 – WASHER 2 – BOLTS & WASHERS
2 – NUT AND WASHER 3 – NUTS & WASHERS
3 – EXHAUST MANIFOLD HEAT SHIELD 4 – EXHAUST MANIFOLD (RIGHT)
5 – BOLTS & WASHERS

(7) Lower the vehicle.

(8) Connect the battery negative cable.

CYLINDER HEAD COVER

A steel backed silicon gasket is used with the cyl-
inder head cover (Fig. 43). This gasket can be used
again.

Fig. 41 Exhaust Manifold Heat Shield—Left Side

1 – WASHER
2 – NUT AND WASHER
3 – EXHAUST MANIFOLD HEAT SHIELD
Fig. 43 Cylinder Head Cover Gasket
1 – CYLINDER HEAD COVER GASKET
(2) Install new bolt and washer assemblies in the
remaining holes (Fig. 42). Start at the center arm
and work outward. Tighten the bolts and nuts to 24 REMOVAL
N·m (18 ft. lbs.) torque. (1) Disconnect the negative cable from the battery.
(3) Position three washers, heat shield and nuts on (2) Disconnect closed ventilation system and evap-
the right side exhaust manifold. Tighten nuts to 24 oration control system from cylinder head cover.
N·m (18 ft. lbs.). (3) Remove the air inlet hose.
(4) Position two washers, heat shield and nuts on (4) Remove cylinder head cover and gasket. The
the left side exhaust manifold. Tighten nuts to 24 gasket may be used again.
N·m (18 ft. lbs.).
(5) Raise the vehicle. INSTALLATION
(6) Assemble the exhaust pipe to the exhaust man- (1) The cylinder head cover gasket can be used
ifold and secure with bolts, nuts and washers. again. Install the gasket onto the head rail.
Tighten these nuts to 27 N·m (20 ft. lbs.) torque.

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 DN 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. shaft retaining bolt, turn engine so the No.1 piston is
(4) Install the air inlet hose. at TDC on the compression stroke.
(5) Connect the negative cable to the battery. (5) Remove rocker arms.
(6) With air hose attached to an adapter installed
ROCKER ARMS AND PUSH RODS in No.1 spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.
REMOVAL (7) Using Valve Spring Compressor Tool
(1) Remove cylinder head cover and gasket. Refer MD-998772A with adaptor 6716A, compress valve
to Cylinder Head Cover in this section for correct spring and remove retainer valve locks and valve
procedure. spring.
(2) Remove the rocker arm bolts and pivots (Fig. (8) Install seals on the exhaust valve stem and
44). Place them on a bench in the same order as position down against valve guides.
removed. (9) The intake valve stem seals should be pushed
(3) Remove the push rods and place them on a firmly and squarely over the valve guide using the
bench in the same order as removed. valve stem as a guide. DO NOT force seal against top
of guide. When installing the valve retainer locks,
compress the spring only enough to install the locks.
(10) Follow the same procedure on the remaining 7
cylinders using the firing sequence 1-8-4-3-6-5-7-2.
Make sure piston in cylinder is at TDC on the valve
spring that is being removed.
(11) Remove adapter from the No.1 spark plug
hole and install spark plugs.
(12) Install rocker arms.
(13) Install covers and coil wire to distributor.
(14) Install air cleaner.
Fig. 44 Rocker Arms (15) Road test vehicle.
1 – ROCKER ARMS
2 – CYLINDER HEAD CYLINDER HEAD
REMOVAL
INSTALLATION
(1) Disconnect the battery negative cable.
(1) Rotate the crankshaft until the “V8” mark lines
(2) Drain cooling system Refer to COOLING SYS-
up with the TDC mark on the timing chain case
TEM.
cover. This mark is located 147° ATDC from the No.1
(3) Remove the intake manifold-to-generator
firing position.
bracket support rod. Remove the generator.
(2) Install the push rods in the same order as
(4) Remove closed crankcase ventilation system.
removed.
(5) Disconnect the evaporation control system.
(3) Install rocker arm and pivot assemblies in the
(6) Remove the air cleaner assembly and air inlet
same order as removed. Tighten the rocker arm bolts
hose.
to 28 N·m (21 ft. lbs.) torque.
(7) Perform fuel system pressure release proce-
CAUTION: DO NOT rotate or crank the engine dur- dure. Refer to FUEL SYSTEM.
ing or immediately after rocker arm installation. (8) Disconnect the fuel supply line.
Allow the hydraulic roller tappets adequate time to (9) Disconnect accelerator linkage and if so
bleed down (about 5 minutes). equipped, the speed control and transmission kick-
down cables.
(4) Install cylinder head cover. (10) Remove distributor cap and wires.
(11) Disconnect the coil wires.
VALVE SPRING AND STEM SEAL (12) Disconnect heat indicator sending unit wire.
(13) Disconnect heater hoses and bypass hose.
REPLACEMENT-IN VEHICLE (14) Remove cylinder head covers and gaskets.
(1) Remove the air cleaner.
(2) Remove cylinder head covers and spark plugs.

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 9 - 108 5.2L ENGINE DN
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. (12) Connect the accelerator linkage and if so
(16) Remove exhaust manifolds. equipped, the speed control and transmission kick-
(17) Remove rocker arm assemblies and push rods. down cables.
Identify to ensure installation in original locations. (13) Install the fuel supply line.
(18) Remove the head bolts from each cylinder (14) Install the generator and drive belt. Tighten
head and remove cylinder heads. Discard the cylin- generator mounting bolt to 41 N·m (30 ft. lbs.)
der head gasket. torque.
(19) Remove spark plugs. (15) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
INSTALLATION (16) Place the cylinder head cover gaskets in posi-
(1) Position the new cylinder head gaskets onto tion and install cylinder head covers. Tighten the
the cylinder block. bolts to 11 N·m (95 in. lbs.) torque.
(2) Position the cylinder heads onto head gaskets (17) Install closed crankcase ventilation system.
and cylinder block. (18) Connect the evaporation control system.
(3) Starting at top center, tighten all cylinder head (19) Install the air cleaner assembly and air inlet
bolts, in sequence, to 68 N·m (50 ft. lbs.) torque (Fig. hose.
45). Repeat procedure, tighten all cylinder head bolts (20) Install the heat shields. Tighten the bolts to
to 143 N·m (105 ft. lbs.) torque. Repeat procedure to 41 N·m (30 ft. lbs.) torque.
confirm that all bolts are at 143 N·m (105 ft. lbs.) (21) Fill cooling system.
torque. (22) Connect the battery negative cable.

VALVES AND VALVE SPRINGS

REMOVAL
(1) Remove the cylinder head. Refer to Cylinder
Head in this section for correct procedure.
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A and adapter 6716A.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.

INSTALLATION
Fig. 45 Cylinder Head Bolt Tightening Sequence (1) Clean valves thoroughly. Discard burned,
warped and cracked valves.
CAUTION: When tightening the rocker arm bolts,
(2) Remove carbon and varnish deposits from
make sure the piston in that cylinder is NOT at
inside of valve guides with a reliable guide cleaner.
TDC. Contact between the valves and piston could
(3) Measure valve stems for wear. If wear exceeds
occur.
0.051 mm (0.002 inch), replace the valve.
(4) Install push rods and rocker arm assemblies in (4) Coat valve stems with lubrication oil and insert
their original position. Tighten the bolts to 28 N·m them in cylinder head.
(21 ft. lbs.) torque. (5) If valves or seats are reground, check valve
(5) Install the intake manifold and throttle body stem height. If valve is too long, replace cylinder
assembly. head.
(6) Install exhaust manifolds. Tighten the bolts (6) Install new seals on all valve guides. Install
and nuts to 34 N·m (25 ft. lbs.) torque. valve springs and valve retainers.
(7) Adjust spark plugs to specifications. Refer to (7) Compress valve springs with Valve Spring
IGNITION SYSTEM. Install the plugs and tighten to Compressor Tool MD-998772A and adapter 6716A,
41 N·m (30 ft. lbs.) torque. install locks and release tool. If valves and/or seats
(8) Install coil wires. are ground, measure the installed height of springs.
(9) Connect heat indicator sending unit wire. Make sure the measurement is taken from bottom of

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 DN 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. If height is greater than 42.86 Cooling System).
mm (1-11/16 inches), install a 1.587 mm (1/16 inch) (5) Remove the vibration damper pulley.
spacer in head counterbore. This should bring spring (6) Remove vibration damper bolt and washer from
height back to normal 41.27 to 42.86 mm (1-5/8 to end of crankshaft.
1-11/16 inch). (7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the
HYDRAULIC TAPPETS puller tool and into the vibration damper (Fig. 46).

REMOVAL
(1) Remove the air cleaner assembly and air inlet
hose.
(2) Remove cylinder head cover, rocker assembly
and push rods. Identify push rods to ensure installa-
tion in original location.
(3) Remove intake manifold, yoke retainer and
aligning yokes.
(4) Slide Hydraulic Tappet Remover/Installer Tool
C-4129-A through opening in cylinder head and seat
tool firmly in the head of tappet.
(5) Pull tappet out of bore with a twisting motion. Fig. 46 Vibration Damper Assembly
1 – SPECIAL TOOL C-3688
If all tappets are to be removed, identify tappets to
ensure installation in original location.
(8) Pull vibration damper off of the crankshaft.
INSTALLATION
(1) If the tappet or bore in cylinder block is scored, INSTALLATION
scuffed, or shows signs of sticking, ream the bore to (1) Position the vibration damper onto the crank-
next oversize. Replace with oversize tappet. shaft.
(2) Lubricate tappets. (2) Place installing tool, part of Puller Tool Set
(3) Install tappets and push rods in their original C-3688 in position and press the vibration damper
positions. Ensure that the oil feed hole in the side of onto the crankshaft (Fig. 47).
the tappet body faces up (away from the crankshaft).
(4) Install aligning yokes with ARROW toward
camshaft.
(5) Install yoke retainer. Tighten the bolts to 23
N·m (200 in. lbs.) torque. Install intake manifold.
(6) Install push rods in original positions.
(7) Install rocker arm.
(8) Install cylinder head cover.
(9) Install air cleaner assembly and air inlet hose.
(10) Start and operate engine. Warm up to normal
operating temperature.

CAUTION: To prevent damage to valve mechanism, Fig. 47 Installing Vibration Damper

engine must not be run above fast idle until all 1 – SPECIAL TOOL C-3688
hydraulic tappets have filled with oil and have
become quiet.
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 183 N·m (135 ft. lbs.) torque.
VIBRATION DAMPER (4) Install the crankshaft pulley. Tighten the pul-
ley bolts to 23 N·m (200 in. lbs.) torque.
REMOVAL (5) Install the serpentine belt (refer to Group 7,
(1) Disconnect the negative cable from the battery. Cooling System).
(2) Remove fan shroud retainer bolts and set (6) Install the cooling system fan. Tighten the
shroud back over engine. bolts to 23 N·m (17 ft. lbs.) torque.

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 9 - 110 5.2L ENGINE DN
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.
(2) Drain cooling system (refer to Group 7, Cooling
System).
(3) Remove the serpentine belt (refer to Group 7,
Cooling System).
(4) Remove water pump (refer to Group 7, Cooling
System).
(5) Remove power steering pump (refer to Group
19, Steering).
(6) Remove vibration damper.
(7) Remove fuel lines (refer to Group 14, Fuel Sys- Fig. 49 Placing Oil Seal on Installation Tool 6635
1 – CRANKSHAFT FRONT OIL SEAL
tem).
2 – INSTALL THIS END INTO SPECIAL TOOL 6635
(8) Loosen oil pan bolts and remove the front bolt
at each side.
(9) Remove the cover bolts. (6) Tighten the 4 lower chain case cover bolts to
(10) Remove chain case cover and gasket using 13N·m (10 ft.lbs.) to prevent the cover from tipping
extreme caution to avoid damaging oil pan gasket. during seal installation.
(11) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal surface of cover (Fig. 48).

Fig. 48 Removal of Front Crankshaft Oil Seal

INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) The water pump mounting surface must be
cleaned.
(3) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket. Fig. 50 Position Tool and Seal onto Crankshaft
Use a small amount of Mopar Silicone Rubber Adhe- 1 – SPECIAL TOOL 6635
sive Sealant, or equivalent, at the joint between tim- 2 – OIL SEAL
3 – TIMING CHAIN COVER
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.
(4) Place the smaller diameter of the oil seal over (7) Using the vibration damper bolt, tighten the
Front Oil Seal Installation Tool 6635 (Fig. 49). Seat bolt to draw the seal into position on the crankshaft
the oil seal in the groove of the tool. (Fig. 51).
(5) Position the seal and tool onto the crankshaft (8) Loosen the 4 bolts tightened in step 4 to allow
(Fig. 50). realignment of front cover assembly.

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 DN 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.
(2) Place timing chain around both sprockets.
(3) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(4) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(5) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 52).

Fig. 51 Installing Oil Seal

1 – SPECIAL TOOL 6635
2 – TIMING CHAIN COVER

(9) Tighten chain case cover bolts to 41 N·m (30 ft.

lbs.) torque. Tighten oil pan bolts to 24 N·m (215 in.
lbs.) torque.
(10) Remove the vibration damper bolt and seal
installation tool.
(11) Install vibration damper.
(12) Install water pump and housing assembly Fig. 52 Alignment of Timing Marks
using new gaskets (refer to Group 7, Cooling Sys- 1 – TIMING MARKS
tem). Tighten bolts to 41 N·m (30 ft. lbs.) torque.
(13) Install power steering pump (refer to Group (6) Install the camshaft bolt. Tighten the bolt to 68
19, Steering). N·m (50 ft. lbs.) torque.
(14) Install the serpentine belt (refer to Group 7, (7) Check camshaft end play. The end play should
Cooling System). be 0.051-0.152 mm (0.002-0.006 inch) with a new
(15) Install the cooling system fan. Tighten the thrust plate and up to 0.254 mm (0.010 inch) with a
bolts to 23 N·m (17 ft. lbs.) torque. used thrust plate. If not within these limits install a
(16) Position the fan shroud and install the bolts. new thrust plate.
Tighten the bolts to 11 N·m (95 in. lbs.) torque. (8) Install the timing chain cover.
(17) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure). CAMSHAFT
(18) Connect the negative cable to the battery.
NOTE: The camshaft has an integral oil pump and
TIMING CHAIN distributor drive gear (Fig. 53).

REMOVAL
(1) Disconnect battery negative cable. REMOVAL
(2) Remove Timing Chain Cover. Refer to Timing (1) Remove the radiator. Refer to Group 7, Cooling
Chain Cover in this section for correct procedure. for the correct procedures.
(3) Re-install the vibration damper bolt finger (2) Remove the A/C Condenser (if equipped)
tight. Using a suitable socket and breaker bar, rotate (3) Remove the engine cover.

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 9 - 112 5.2L ENGINE DN
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. 55).

Fig. 53 Camshaft and Sprocket Assembly

1 – THRUST PLATE
2 – OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL
WITH CAMSHAFT
3 – CAMSHAFT SPROCKET

(4) Remove intake manifold. Refer to Intake Man-

ifold in this section for the correct procedure.
(5) Remove cylinder head covers.
Fig. 55 Camshaft Holding Tool C-3509 (Installed
(6) Remove timing case cover and timing chain.
Position)
(7) Remove rocker arms.
1 – SPECIAL TOOL C-3509
(8) Remove push rods and tappets. Identify each
2 – DRIVE GEAR
part so it can be installed in its original location. 3 – DISTRIBUTOR LOCK BOLT
(9) Remove distributor and lift out the oil pump
and distributor drive shaft.
(10) Remove camshaft thrust plate, note location of (3) Hold tool in position with a distributor lock-
oil tab (Fig. 54). plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block. Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in
thrust plate. Tighten bolts to 24 N·m (210 in. lbs.)
torque. Top edge of tab should be flat against thrust
plate in order to catch oil for chain lubrication.
(5) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(6) Place timing chain around both sprockets.
(7) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(8) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(9) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 56).
Fig. 54 Timing Chain Oil Tab Installation
(10) Install the camshaft bolt/cup washer. Tighten
1 – THRUST PLATE FRONT SIDE
bolt to 68 N·m (50 ft. lbs.) torque.
2 – CHAIN OIL TAB
3 – THRUST PLATE REAR SIDE
(11) Measure camshaft end play. Refer to Specifica-
tions for proper clearance. If not within limits install
a new thrust plate.
(11) Install a long bolt into front of camshaft to aid (12) Each tappet reused must be installed in the
in removal of the camshaft. Remove camshaft, being same position from which it was removed. When
careful not to damage cam bearings with the cam camshaft is replaced, all of the tappets must be
lobes. replaced.

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 DN 5.2L ENGINE 9 - 113
REMOVAL AND INSTALLATION (Continued)

Fig. 56 Alignment of Timing Marks

1 – TIMING MARKS Fig. 57 Camshaft Bearings Removal/Installation with
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.
(15) Install rocker arms.
(16) Install timing case cover. CRANKSHAFT MAIN BEARINGS
(17) Install cylinder head covers.
(18) Install intake manifold. REMOVAL
(19) Install the engine cover. (1) Remove the oil pan.
(20) Install the A/C Condenser (if equipped). (2) Remove the oil pump from the rear main bear-
(21) Install the radiator. Refer to Group 7, Cooling ing cap.
for the correct procedures. (3) Identify bearing caps before removal. Remove
(22) Refill cooling system. Refer to Group 7, Cool- bearing caps one at a time.
ing for the correct procedures. (4) Remove upper half of bearing by inserting
(23) Start engine check for leaks. Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 58).
CAMSHAFT BEARINGS (5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
REMOVAL
NOTE: This procedure requires that the engine is
removed from the vehicle.

(1) With engine completely disassembled, drive out

rear cam bearing core plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell. Drive
out bearing shells (Fig. 57).

INSTALLATION
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter.
(2) Position rear bearing in the tool. Install horse-
shoe lock and by reversing removal procedure, care-
Fig. 58 Upper Main Bearing Removal and
fully drive bearing shell into place.
Installation with Tool C-3059
(3) Install remaining bearings in the same man-
1 – SPECIAL TOOL C-3059
ner. Bearings must be carefully aligned to bring oil 2 – BEARING
holes into full register with oil passages from the 3 – SPECIAL TOOL C-3059
main bearing. If the camshaft bearing shell oil holes 4 – BEARING
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft. Be sure this plug does not leak.

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 9 - 114 5.2L ENGINE DN
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.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 58).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Tool C-3059. Fig. 60 Distributor Driveshaft Bushing Installation
(3) Install the bearing caps. Clean and oil the bolts. 1 – SPECIAL TOOL C-3053
Tighten the capbolts to 115 N·m (85 ft. lbs.) torque. 2 – BUSHING
(4) Install the oil pump.
(5) Install the oil pan.
(6) Start engine check for leaks. CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
DISTRIBUTOR DRIVE SHAFT BUSHING occur.

REMOVAL
(1) Remove distributor, refer to Group 8D, Ignition
Systems for the proper procedure.
(2) Remove the intake manifold. Refer to Intake
Manifold in this section for correct procedure.
(3) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and thread down until a
tight fit is obtained (Fig. 59).
(4) Hold puller screw and tighten puller nut until
bushing is removed.
Fig. 61 Burnishing Distributor Driveshaft Bushing
1 – SPECIAL TOOL C-3053
2 – BUSHING

(4) Install the intake manifold.

DISTRIBUTOR INSTALLATION
NOTE: Before installing the distributor, the oil
pump drive shaft must be aligned to number one
cylinder.
Fig. 59 Distributor Driveshaft Bushing Removal
1 – SPECIAL TOOL C-3052
(1) Rotate crankshaft until No.1 cylinder is at top
2 – BUSHING
dead center on the firing stroke.
(2) When in this position, the timing mark of
INSTALLATION vibration damper should be under “0” on the timing
(1) Slide new bushing over burnishing end of Dis- indicator.
tributor Drive Shaft Bushing Driver/Burnisher Tool (3) Install the shaft so that after the gear spirals
C-3053. Insert the tool and bushing into the bore. into place, it will index with the oil pump shaft. The
(2) Drive bushing and tool into position, using a slot on top of oil pump shaft should be aligned
hammer (Fig. 60). towards the left front intake manifold attaching bolt
(3) As the burnisher is pulled through the bushing, hole (Fig. 62).
the bushing is expanded tight in the block and bur- (4) Install distributor, refer to Group 8D, Ignition
nished to correct size (Fig. 61). DO NOT ream this Systems for the proper procedure.
bushing.

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 DN 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. Refer to Checking Dis-
tributor Position following the Distributor Installa-
tion section in Group 8D, Ignition system.
Do not attempt to adjust ignition timing by
rotating the distributor. It has no effect on igni-
tion timing. Adjusting distributor position will Fig. 62A Throttle Valve Cable Removal/Installation
effect fuel synchronization only. 1 – TRANSMISSION THROTTLE VALVE CABLE BRACKET
2 – AIR INLET DUCT
OIL PAN 3 – TRANSMISSION THROTTLE VALVE CABLE

REMOVAL (16) Remove transmission torque converter inspec-

tion cover.
2WD (17) Disconnect rear support cushion from cross-
(1) Disconnect the negative cable from the battery. member.
(2) Remove air cleaner assembly. (18) Raise rear of transmission away from cross-
(3) Remove engine oil dipstick. member.
(4) Disconnect distributor cap and position away (19) Remove oil pan and one-piece gasket.
from cowl.
(5) Remove the fan shroud. Refer to COOLING 4WD
SYSTEM. (1) Disconnect the negative cable from the battery.
(6) Disconnect throttle valve cable from throttle (2) Remove engine oil dipstick.
body and mounting bracket (Fig. 62A). (3) Raise vehicle.
(7) Raise vehicle. (4) Drain engine oil.
(8) Drain engine oil. (5) Remove front driving axle. Refer to DIFFER-
(9) Remove exhaust pipe from exhaust manifolds. ENTIAL and DRIVELINE.
(10) Remove engine mount insulator through bolts. (6) Remove both engine mount support brackets.
(11) Raise engine by way of oil pan using a block (7) Remove transmission torque converter inspec-
of wood between the jack and oil pan. tion cover.
(12) When engine is high enough, place mount (8) Remove oil pan and one-piece gasket.
through bolts in the engine mount attaching points
on the frame brackets. INSTALLATION
(13) Lower engine so bottom of engine mounts rest
on the replacement bolts placed in the engine mount 2WD
frame brackets. (1) Fabricate 4 alignment dowels from 5/16 x 1 1/2
(14) Remove transmission to engine braces. inch bolts. Cut the head off the bolts and cut a slot
(15) Remove starter. Refer to STARTING SYS- into the top of the dowel. This will allow easier
TEMS. installation and removal with a screwdriver (Fig. 63).

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 9 - 115A 5.2L ENGINE DN
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.
Tighten bolts to 28 N·m (250 in. lbs.).
(11) Raise engine by way of oil pan with a wood
block placed between jack and oil pan.
(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.
(14) Install transmission torque converter inspec-
tion cover.
Fig. 63 Fabrication of Alignment Dowels
(15) Install engine to transmission braces.
1 – 1 1/2” x 5/16” BOLT
2 – DOWEL
(16) Install exhaust pipe.
3 – SLOT (17) Lower vehicle.
(18) Position throttle valve cable into bracket, then
attach to throttle body (Fig. 62A).
(2) Install the dowels in the cylinder block (Fig. 64). (19) Connect the distributor cap.
(20) Install dipstick.
(21) Install fan shroud.
(22) Install air cleaner assembly.
(23) Connect the negative cable to the battery.
(24) Fill crankcase with oil to proper level.

4WD
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier
installation and removal with a screwdriver (Fig. 63).
(2) Install the dowels in the cylinder block (Fig.
64).
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
Fig. 64 Position of Dowels in Cylinder Block (6) Install the oil pan bolts. Tighten the bolts to 24
1 – DOWEL N·m (215 in. lbs.) torque.
2 – DOWEL
(7) Remove the dowels. Install the remaining oil
3 – DOWEL
pan bolts. Tighten these bolts to 24 N·m (215 in. lbs.)
4 – DOWEL
torque.
(8) Install the drain plug. Tighten drain plug to 34
(3) Apply small amount of Mopar Silicone Rubber N·m (25 ft. lbs.) torque.
Adhesive Sealant, or equivalent in the corner of the (9) Install transmission inspection cover.
cap and the cylinder block. (10) Install engine mount support brackets and
(4) Slide the one-piece gasket over the dowels and insulators.
onto the block. (11) Install front drive axle. Refer to DIFFEREN-
(5) Position the oil pan over the dowels and onto TIAL and DRIVELINE.
the gasket. (12) Lower vehicle.
(6) Install the oil pan bolts. Tighten the bolts to 24 (13) Connect the distributor cap.
N·m (215 in. lbs.) torque. (14) Install dipstick.
(7) Remove the dowels. Install the remaining oil (15) Connect the negative cable to the battery.
pan bolts. Tighten these bolts to 24 N·m (215 in. lbs.) (16) Fill crankcase with oil to proper level.
torque.

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 9 - 116 5.2L ENGINE DN
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
REMOVAL numbered side of the connecting rod.
(1) Remove the engine from the vehicle. (5) Rotate crankshaft so that the connecting rod
(2) Remove the cylinder head. journal is on the center of the cylinder bore. Be sure
(3) Remove the oil pan. connecting rod and cylinder bore number are the
(4) Remove top ridge of cylinder bores with a reli- same. Insert rod and piston into cylinder bore and
able ridge reamer before removing pistons from cyl- guide rod over the crankshaft journal.
inder block. Be sure to keep tops of pistons covered (6) Tap the piston down in cylinder bore, using a
during this operation. hammer handle. At the same time, guide connecting
(5) Be sure the connecting rod and connecting rod rod into position on crankshaft journal.
cap are identified with the cylinder number. Remove (7) The notch or groove on top of piston must be
connecting rod cap. Install connecting rod bolt guide pointing toward front of engine. The larger chamfer
set on connecting rod bolts. of the connecting rod bore must be installed toward
(6) Pistons and connecting rods must be removed crankshaft journal fillet.
from top of cylinder block. When removing piston and (8) Install rod caps. Be sure connecting rod, con-
connecting rod assemblies, rotate crankshaft to cen- necting rod cap and cylinder bore number are the
ter the connecting rod in the cylinder bore and at same. Install nuts on cleaned and oiled rod bolts and
BDC. Be careful not to nick crankshaft journals. tighten nuts to 61 N·m (45 ft. lbs.) torque.
(7) After removal, install bearing cap on the mat- (9) Install the oil pan.
ing rod. (10) Install the cylinder head.
(11) Install the engine into the vehicle.
INSTALLATION
(1) Be sure that compression ring gaps are stag- CRANKSHAFT
gered so that neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make REMOVAL
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 65). NOTE: This procedure can be done in vehicle.
However the transmission must be removed first.

(1) If crankshaft is to be removed while engine is

in vehicle remove the transmission. Refer to Group
21, for correct procedure.
(2) Remove the oil pan.
(3) Remove the oil pump from the rear main bear-
ing cap.
(4) Remove the vibration damper.
(5) Remove the timing chain cover.
(6) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.

CAUTION: Support crankshaft before removing

main bearing caps. failure to do so will allow the
crankshaft to fall damaging the crankshaft.

Fig. 65 Proper Ring Installation (7) Using a suitable jack, support the crankshaft.
1 – OIL RING SPACER GAP (8) Identify main bearing caps before removal.
2 – SECOND COMPRESSION RING GAP OIL RING RAIL GAP Remove main bearing caps and bearings one at a
(TOP)
3 – OIL RING RAIL GAP (BOTTOM)
time.
4 – TOP COMPRESSION RING GAP (9) Lower the crankshaft out of the block.
(10) Remove and discard the crankshaft rear oil
seals.
(3) Immerse the piston head and rings in clean (11) Remove and discard the front crankshaft oil
engine oil. Slide Piston Ring Compressor Tool C-385 seal.
over the piston and tighten with the special wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.

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 DN 5.2L ENGINE 9 - 117
REMOVAL AND INSTALLATION (Continued)
INSTALLATION Apply enough sealant until a small amount is
(1) Clean Gasket Maker residue and sealant from squeezed out. Withdraw nozzle and wipe excess seal-
the cylinder block and rear cap mating surface. Do ant off the oil pan seal groove.
this before applying the Mopart Gasket Maker and (15) Install new front crankshaft oil seal.
the installation of rear cap. (16) Immediately install the oil pan.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of Mopart Gasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 66). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application. Fig. 67 Apply Sealant to Bearing Cap to Block Joint
1 – MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE
TIP
2 – SEALANT APPLIED
3 – CYLINDER BLOCK
4 – REAR MAIN BEARING CAP

(17) If the transmission was removed, install the

transmission.

OIL PUMP
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from rear main bearing
cap.
Fig. 66 Sealant Application to Bearing Cap
1 – .25 DROP OF LOCTITE 515 ON BOTH SIDES OF REAR INSTALLATION
MAIN CAP (1) Install oil pump. During installation slowly
rotate pump body to ensure driveshaft-to-pump rotor
(8) To align the bearing cap, use cap slot, align- shaft engagement.
ment dowel and cap bolts. DO NOT remove excess (2) Hold the oil pump base flush against mating
material after assembly. DO NOT strike rear cap surface on No.5 main bearing cap. Finger tighten
more than 2 times for proper engagement. pump attaching bolts. Tighten attaching bolts to 41
(9) Clean and oil all cap bolts. Install all main N·m (30 ft. lbs.) torque.
bearing caps. Install all cap bolts and alternately (3) Install the oil pan.
tighten to 115 N·m (85 ft. lbs.) torque.
(10) Install oil pump. CRANKSHAFT OIL SEAL—FRONT
(11) Install the timing chain cover. The oil seal can be replaced without removing the
(12) Install the vibration damper. timing chain cover provided the cover is not mis-
(13) Position the connecting rods onto the crank- aligned.
shaft and install the rod bearing caps. Tighten the (1) Disconnect the negative cable from the battery.
nuts to 61 N·m (45 ft. lbs.). (2) Remove vibration damper.
(14) Apply Mopart Silicone Rubber Adhesive Seal- (3) If front seal is suspected of leaking, check front
ant, or equivalent, at bearing cap to block joint to oil seal alignment to crankshaft. The seal installa-
provide cap to block and oil pan sealing (Fig. 67). tion/alignment tool 6635, should fit with minimum

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 9 - 118 5.2L ENGINE DN
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.
(5) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 68). Seat
the oil seal in the groove of the tool.

Fig. 69 Position Tool and Seal onto Crankshaft

1 – SPECIAL TOOL 6635
2 – OIL SEAL
Fig. 68 Placing Oil Seal on Installation Tool 6635 3 – TIMING CHAIN COVER
1 – CRANKSHAFT FRONT OIL SEAL
2 – INSTALL THIS END INTO SPECIAL TOOL 6635

(6) Position the seal and tool onto the crankshaft

(Fig. 69).
(7) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 70).
(8) Remove the vibration damper bolt and seal
installation tool.
(9) Inspect the seal flange on the vibration
damper.
(10) Install the vibration damper.
(11) Connect the negative cable to the battery.

CRANKSHAFT OIL SEALS—REAR

The service seal is a 2 piece, viton seal. The upper
seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
The lower seal half can only be installed with the
rear main bearing cap removed.

UPPER SEAL —CRANKSHAFT REMOVED Fig. 70 Installing Oil Seal

1 – SPECIAL TOOL 6635
REMOVAL 2 – TIMING CHAIN COVER
(1) Remove the crankshaft. Discard the old upper
seal. INSTALLATION
(1) Clean the cylinder block rear cap mating sur-
face. Make sure the seal groove is free of debris.

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 DN 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.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of Mopart Gasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 71). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application. Fig. 72 Apply Sealant to Bearing Cap to Block Joint
1 – MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE
TIP
2 – SEALANT APPLIED
3 – CYLINDER BLOCK
4 – REAR MAIN BEARING CAP

UPPER SEAL —CRANKSHAFT INSTALLED

REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal.
(4) Carefully remove and discard the old upper oil
seal.

Fig. 71 Sealant Application to Bearing Cap INSTALLATION

1 – MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS (1) Clean the cylinder block mating surfaces before
2 – LOCTITE 518 (OR EQUIVALENT) oil seal installation. Check for burr at the oil hole on
3 – CAP ALIGNMENT SLOT the cylinder block mating surface to rear cap.
4 – REAR MAIN BEARING CAP
(2) Lightly oil the new upper seal lips with engine
oil. To allow ease of installation of the seal, loosen at
(8) To align the bearing cap, use cap slot, align- least the 2 main bearing caps forward of the rear
ment dowel and cap bolts. DO NOT remove excess bearing cap.
material after assembly. DO NOT strike rear cap (3) Rotate the new upper seal into the cylinder
more than 2 times for proper engagement. block being careful not to shave or cut the outer sur-
(9) Clean and oil all cap bolts. Install all main face of the seal. To assure proper installation, use the
bearing caps. Install all cap bolts and alternately installation tool provided with the kit. Install the
tighten to 115 N·m (85 ft. lbs.) torque. new seal with the white paint facing towards the
(10) Install oil pump. rear of the engine.
(11) Apply Mopart Silicone Rubber Adhesive Seal- (4) Install the new lower rear bearing oil seal into
ant, or equivalent, at bearing cap to block joint to the bearing cap with the white paint facing towards
provide cap to block and oil pan sealing (Fig. 72). the rear of the engine.
Apply enough sealant until a small amount is (5) Apply 5 mm (0.20 in) drop of Mopart Gasket
squeezed out. Withdraw nozzle and wipe excess seal- Maker, or equivalent, on each side of the rear main
ant off the oil pan seal groove. bearing cap (Fig. 71). DO NOT over apply sealant or
(12) Install new front crankshaft oil seal. allow the sealant to contact the rubber seal. Assem-
(13) Immediately install the oil pan. ble bearing cap to cylinder block immediately after
sealant application. Be sure the white paint faces
toward the rear of the engine.

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 9 - 120 5.2L ENGINE DN
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. DO NOT strike rear cap galleries behind the camshaft thrust plate (Fig. 73).
more than 2 times for proper engagement. This will reduce internal leakage and help maintain
(7) Install the rear main bearing cap with cleaned higher oil pressure at idle.
and oiled cap bolts. Alternately tighten ALL cap bolts
to 115 N·m (85 ft. lbs.) torque.
(8) Install oil pump.
(9) Apply Mopart Silicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 72).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(10) Immediately install the oil pan.

LOWER SEAL
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Remove the rear main bearing cap and discard
the old lower seal.

INSTALLATION Fig. 73 Location of Cup Plugs in Oil Galleries

(1) Clean the rear main cap mating surfaces 1 – CUP PLUGS
including the oil pan gasket groove.
(2) Carefully install a new upper seal (refer to
REMOVAL
Upper Seal Replacement - Crankshaft Installed pro-
(1) Using a blunt tool such as a drift or a screw-
cedure above).
driver and a hammer, strike the bottom edge of the
(3) Lightly oil the new lower seal lips with engine
cup plug (Fig. 74).
oil.
(2) With the cup plug rotated, grasp firmly with
(4) Install a new lower seal in bearing cap with
pliers or other suitable tool and remove plug (Fig.
the white paint facing the rear of engine.
74).
(5) Apply 5 mm (0.20 in) drop of Mopart Gasket
Maker, or equivalent, on each side of the rear main
INSTALLATION
bearing cap (Fig. 71). DO NOT over apply sealant or
Thoroughly clean inside of cup plug hole in cylin-
allow the sealant to contact the rubber seal. Assem-
der block or head. Be sure to remove old sealer.
ble bearing cap to cylinder block immediately after
Be certain the new plug is cleaned of all oil or
sealant application.
grease.
(6) To align the bearing cap, use cap slot, align-
(1) Coat edges of plug and core hole with Mopart
ment dowel and cap bolts. DO NOT remove excess
Gasket Maker, or equivalent.
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement. CAUTION: DO NOT drive cup plug into the casting,
(7) Install the rear main bearing cap with cleaned as restricted coolant flow can result and cause seri-
and oiled cap bolts. Alternately tighten the cap bolts ous engine problems.
to 115 N·m (85 ft. lbs.) torque.
(8) Install oil pump. (2) Using proper plug drive, drive cup plug into
(9) Apply Mopart Silicone Rubber Adhesive Seal- hole. The sharp edge of the plug should be at least
ant, or equivalent, at bearing cap to block joint to 0.50 mm (0.020 in.) inside the lead-in chamfer.
provide cap to block and oil pan sealing (Fig. 72). (3) It is not necessary to wait for curing of the
Apply enough sealant until a small amount is sealant. The cooling system can be filled and the
squeezed out. Withdraw nozzle and wipe excess seal- vehicle placed in service immediately.
ant off the oil pan seal groove.
(10) Immediately install the oil pan.

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 DN 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 – REMOVE PLUG WITH PLIERS
3 – STRIKE HERE WITH HAMMER Fig. 76 Measuring Valve Guide Wear
4 – DRIFT PUNCH 1 – VALVE
5 – CUP PLUG 2 – SPECIAL TOOL C-3339

DISASSEMBLY AND ASSEMBLY (3) Move valve to and from the indicator. The total
dial indicator reading should not exceed 0.432 mm
VALVE SERVICE (0.017 inch). Ream the guides for valves with over-
size stems if dial indicator reading is excessive or if
VALVE GUIDES the stems are scuffed or scored.
Measure valve stem guide clearance as follows: (4) Service valves with oversize stems are avail-
(1) Install Valve Guide Sleeve Tool C-3973 over able as shown below.
valve stem and install valve (Fig. 75). The special REAMER SIZES CHART
sleeve places the valve at the correct height for
checking with a dial indicator.
REAMER O/S VALVE GUIDE SIZE
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 - 0.317 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) (0.328 - 0.329 in.)

(5) Slowly turn reamer by hand and clean guide

thoroughly before installing new valve. Ream the
valve guides from standard to 0.381 mm (0.015
inch). Use a 2 step procedure so the valve
guides are reamed true in relation to the valve
Fig. 75 Positioning Valve with Tool C-3973 seat:
1 – VALVE
• Step 1—Ream to 0.0763 mm (0.003 inch).
2 – SPACER TOOL
• Step 2—Ream to 0.381 mm (0.015 inch).

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 9 - 122 5.2L ENGINE DN
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 – MARGIN
2 – VALVE SPRING RETAINER LOCK GROOVE
3 – STEM
4 – FACE

VALVE SEATS
Fig. 77 Valve Face and Seat Angles
1 – CONTACT POINT
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 79).
ITEM DESCRIPTION SPECIFICATION

A SEAT WIDTH - 1.016 - 1.524

mm
INTAKE (0.040 - 0.060
in.)
EXHAUST 1.524 - 2.032
mm
(0.060 - 0.080
in.)

B FACE ANGLE
(INT. AND 431⁄4° - 433⁄4°
EXT.)

C SEAT ANGLE
(INT. AND 44 Fig. 79 Refacing Valve Seats
1 – STONE
EXT.) 1⁄4° - 443⁄4°
2 – PILOT
D CONTACT 3 – VALVE SEAT
4 – SHROUD
SURFACE —

(1) When refacing valve seats, it is important that

VALVES the correct size valve guide pilot be used for reseat-
Inspect the remaining margin after the valves are ing stones. A true and complete surface must be
refaced (Fig. 78). Valves with less than 1.190 mm obtained.
(0.047 inch) margin should be discarded.

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 DN 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. To do (a) Remove cotter pin. Drill a 3.175 mm (1/8
this, coat valve seat LIGHTLY with Prussian blue inch) hole into the relief valve retainer cap and
then set valve in place. Rotate the valve with light insert a self-threading sheet metal screw.
pressure. If the blue is transferred to the center of (b) Clamp screw into a vise and while support-
valve face, contact is satisfactory. If the blue is trans- ing oil pump, remove cap by tapping pump body
ferred to the top edge of valve face, lower valve seat using a soft hammer. Discard retainer cap and
with a 15° stone. If the blue is transferred to bottom remove spring and relief valve (Fig. 81).
edge of valve face raise valve seat with a 60° stone.
(4) When seat is properly positioned the width of
intake seats should be 1.016-1.524 mm (0.040-0.060
inch). The width of the exhaust seats should be
1.524-2.032 mm (0.060-0.080 inch).

VALVE SPRING INSPECTION

Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is 1-5/16 inch. Turn table of
Universals Valve Spring Tester Tool until surface is
in line with the 1-5/16 inch mark on the threaded
stud. Be sure the zero mark is to the front (Fig. 80).
Place spring over stud on the table and lift compress-
ing lever to set tone device. Pull on torque wrench
until ping is heard. Take reading on torque wrench
at this instant. Multiply this reading by 2. This will
give the spring load at test length. Fractional mea- Fig. 81 Oil Pressure Relief Valve
surements are indicated on the table for finer adjust- 1 – OIL PUMP ASSEMBLY
ments. Refer to specifications to obtain specified 2 – COTTER PIN
height and allowable tensions. Discard the springs 3 – RELIEF VALVE
that do not meet specifications. 4 – RETAINER CAP
5 – SPRING

(2) Remove oil pump cover (Fig. 82).

(3) Remove pump outer rotor and inner rotor with
shaft (Fig. 82).
(4) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.

ASSEMBLE
(1) Install pump rotors and shaft, using new parts
as required.
(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N·m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
Fig. 80 Testing Valve Spring for Compressed (4) Tap on a new retainer cap.
Length (5) Prime oil pump before installation by filling
1 – TORQUE WRENCH rotor cavity with engine oil.
2 – VALVE SPRING TESTER

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 9 - 124 5.2L ENGINE DN
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.
Fig. 82 Oil Pump If damaged, use a new gasket.
1 – INNER ROTOR AND SHAFT
2 – BODY CYLINDER HEAD ASSEMBLY
3 – DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 – COTTER PIN CLEANING
5 – RETAINER CAP Clean all surfaces of cylinder block and cylinder
6 – SPRING heads.
7 – RELIEF VALVE
Clean cylinder block front and rear gasket surfaces
8 – LARGE CHAMFERED EDGE
9 – BOLT
using a suitable solvent.
10 – COVER
11 – OUTER ROTOR INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness
CYLINDER BLOCK exceeds 0.00075 mm/mm (0.00075 inch/inch) times
the span length in inches in any direction, either
DISASSEMBLE replace head or lightly machine the head surface.
With Engine removed from vehicle: FOR EXAMPLE: A 305 mm (12 inch) span is
(1) Remove the cylinder heads. refer to Cylinder 0.102 mm (0.004 inch) out-of-flat. The allowable out-
Head in this section for correct procedure. of-flat is 305 X 0.00075 (12 X 0.00075) equals 0.23
(2) Remove the exhaust manifolds. Refer to mm (0.009 inch). This amount of out-of-flat is accept-
Exhaust Manifolds in this section. able.
(3) Remove the oil pan. Refer to Oil Pan in this The cylinder head surface finish should be
section. 1.78-3.00 microns (70-125 microinches).
(4) Remove the piston and connecting rod assem-
blies. Refer to Piston and Connecting Rod in this sec- PISTON AND CONNECTING ROD ASSEMBLY
tion.
(5) Remove the crankshaft. Refer to Crankshaft in INSPECTION
this section. Check the crankshaft connecting rod journal for
(6) Remove the core plugs. excessive wear, taper and scoring.
Check the cylinder block bore for out-of-round,
ASSEMBLE taper, scoring and scuffing.
(1) Install the core plugs. Check the pistons for taper and elliptical shape
(2) Install the crankshaft. before they are fitted into the cylinder bore (Fig. 83).
(3) Install the piston and connecting rods.
(4) Install the oil pan. OIL PAN
(5) Install the cylinder heads.
(6) Install the exhaust manifolds. CLEANING
(7) Install the intake manifold. Clean the block and pan gasket surfaces.
(8) Install the engine into the vehicle. Trim or remove excess sealant film in the rear
main cap oil pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
engine.

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 DN 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. Repair as necessary.
Inspect oil pan mounting flange for bends or distor-
tion. Straighten flange, if necessary.

OIL PUMP
INSPECTION
Mating surface of the oil pump cover should be
smooth. Replace pump assembly if cover is scratched
or grooved.
Lay a straightedge across the pump cover surface
(Fig. 84). If a 0.038 mm (0.0015 inch) feeler gauge
Fig. 83 Piston Measurements can be inserted between cover and straightedge,
1 – 49.53 mm pump assembly should be replaced.
(1.95 IN.)

PISTON MEASUREMENT CHART

PISTON A DIA = PISTON BORE
SIZE DIAMETER DIAMETER
MIN. MAX. MIN. MAX.
mm mm mm mm (in.)
(in.) (in.) (in.)
A — — — —
B 101.580 101.592 101.605 101.618
(3.9992) (3.9997) (4.0002) (4.0007)
C 101.592 101.605 101.618 101.630
(3.9997) (4.0002) (4.0007) (4.0012)
Fig. 84 Checking Oil Pump Cover Flatness
D 101.605 101.618 101.630 101.643 1 – COVER
(4.0002) (4.0007) (4.0012) (4.0017) 2 – STRAIGHT EDGE
3 – FEELER GAUGE
E — — — —
DESCRIPTION SPECIFICATION Measure thickness and diameter of OUTER rotor.
PISTON PIN 25.007 - 25.015 mm If outer rotor thickness measures 20.9 mm (0.825
BORE (.9845 -.9848 in.) inch) or less or if the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 85).
RING GROOVE If inner rotor measures 20.9 mm (0.825 inch) or
HEIGHT less, replace inner rotor and shaft assembly (Fig. 86).
OIL RAIL 4.033 - 4.058 mm Slide outer rotor into pump body. Press rotor to the
(.1588 -.1598 in.) side with your fingers and measure clearance
COMPRESSION 1.529 - 1.554 mm between rotor and pump body (Fig. 87). If clearance
RAIL is 0.356 mm (0.014 inch) or more, replace oil pump
(.0602 -.0612 in.) assembly.
TOTAL FINISHED 470.8 6 2 grams Install inner rotor and shaft into pump body. If
WEIGHT (16.607 6.0706 ounces) clearance between inner and outer rotors is 0.203
mm (0.008 inch) or more, replace shaft and both
rotors (Fig. 88).

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 9 - 126 5.2L ENGINE DN
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. If a feeler gauge of 0.102 mm
(0.004 inch) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig.
89).

Fig. 86 Measuring Inner Rotor Thickness

Fig. 89 Measuring Clearance Over Rotors

1 – STRAIGHT EDGE
2 – FEELER GAUGE

Fig. 87 Measuring Outer Rotor Clearance in

Housing Inspect oil pressure relief valve plunger for scoring
1 – PUMP BODY and free operation in its bore. Small marks may be
2 – OUTER ROTOR removed with 400-grit wet or dry sandpaper.
3 – FEELER GAUGE The relief valve spring has a free length of approx-
imately 49.5 mm (1.95 inches). The spring should
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring that fails
to meet these specifications (Fig. 90).

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 DN 5.2L ENGINE 9 - 127
CLEANING AND INSPECTION (Continued)
If oil pressure was low and pump is within specifi- • The cylinder bores show a taper of more than
cations, inspect for worn engine bearings or other 0.254 mm (0.010 inch).
reasons for oil pressure loss. • The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.
Refer to Standard Service Procedures in the begin-
ning of this Group for the proper honing of cylinder
bores.

INTAKE MANIFOLD
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
Fig. 90 Proper Installation of Retainer Cap all foreign material).
1 – RETAINER CAP
2 – CHAMFER INSPECTION
3 – COTTER KEY Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
CYLINDER BLOCK
EXHAUST MANIFOLD
CLEANING
Clean cylinder block thoroughly and check all core CLEANING
hole plugs for evidence of leaking. Clean mating surfaces on cylinder head and mani-
fold, wash with solvent and blow dry with com-
INSPECTION pressed air.
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of- INSPECTION
round and taper with Cylinder Bore Indicator Tool Inspect manifold for cracks, Inspect mating sur-
C-119. The cylinder block should be bored and honed faces of manifold for flatness with a straight edge.
with new pistons and rings fitted if: Seal surfaces must be flat within 0.1 mm (0.004 inch)
• The cylinder bores show more than 0.127 mm overall.
(0.005 inch) out-of-round.

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 9 - 128 5.2L ENGINE DN

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.)
Engine Type 90° V-8 OHV No. 2 50.343 – 50.368 mm
(1.982 – 1.983 in.)
Bore and Stroke 99.3 x 84.0 mm
No. 3 49.962 – 49.987 mm
(3.91 x 3.31 in.)
(1.967 – 1.968 in.)
Displacement 5.2L No. 4 49.555 – 49.581 mm
(318 c.i.) (1.951 – 1.952 in.)
Compression Ratio 9.1:1 No. 5 39.637 – 39.662 mm
(1.5605 – 1.5615 in.)
Firing Order 1–8–4–3–6–5–7–2
Bearing to Journal
Lubrication Pressure Feed— Clearance
Full Flow Filtration Standard 0.0254 – 0.0762 mm
Cooling System Liquid Cooled— (0.001 – 0.003 in.)
Forced Circulation Service Limit 0.127 mm
(0.005 in.)
Cylinder Block Cast Iron
End Play 0.051 – 0.254 mm
Crankshaft Nodular Iron
(0.002 – 0.010 in.)
Cylinder Head Cast Iron
CONNECTING RODS
Combustion Chambers Wedge-High Swirl
Piston Pin bore Diameter 24.966 – 24.978 mm
Valve shrouding
(0.9829 – 0.9834 in.)
Camshaft Nodular Cast Iron
Side Clearance 0.152 – 0.356 mm
Pistons Aluminum Alloy w/strut (0.006 – 0.014 in.)
Connecting Rods Forged Steel CRANKSHAFT
Cylinder Compression 689.5 kPa Rod Journal
Pressure (Min.) (100 psi) Diameter 53.950 – 53.975 mm
CAMSHAFT (2.124 – 2.125 in.)
Out of Round (Max.) 0.0254 mm
Bearing Diameter
(0.001 in.)
No. 1 50.800 – 50.825 mm
Taper (Max.) 0.0254 mm
(2.000 – 2.001 in.)
(0.001 in.)
No. 2 50.394 – 50.419 mm
Bearing Clearance 0.013 – 0.056 mm
(1.984 – 1.985 in.)
(0.0005 – 0.0022 in.)
No. 3 50.013 – 50.038 mm
Service Limit 0.0762 mm
(1.969 – 1.970 in.)
(0.003 in.)
No. 4 49.606 – 49.632 mm
(1.953 – 1.954 in.)

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 DN 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.) 0.0254 mm
Width (Finish)
(0.001 in.)
Intake 1.016 – 1.524 mm
Bearing Clearance
(0.040 – 0.060 in.)
(#1 Journal) 0.013 – 0.038 mm
Exhaust 1.524 – 2.032 mm
(0.0005 – 0.0015 in.)
(0.060 – 0.080 in.)
(#2-5 Journals) 0.013 – 0.051 mm
(0.0005 – 0.002 in.) VALVES
Service Limit Face Angle 43.25° – 43.75°
(#1 Journal) 0.0381 mm
Head Diameter
(0.0015 in.)
Intake 48.666 mm
(#2-5 Journals) 0.064 mm
(1.916 in.)
(0.0025 in.)
Exhaust 41.250 mm
End Play 0.051 – 0.178 mm (1.624 in.)
(0.002 – 0.007 in.)
Length (Overall)
Service Limit 0.254 mm
Intake 124.28 – 125.92 mm
(0.010 in.)
(4.893 – 4.918 in.)
CYLINDER BLOCK Exhaust 124.64 – 125.27 mm
Cylinder Bore (4.907 – 4.932 in.)
Diameter 99.308 – 99.371 mm Lift (@ zero lash) 10.973 mm
(3.9098 – 3.9122 in.) (0.432 in.)
Out of Round (Max.) 0.025 mm
Stem Diameter 7.899 – 7.925 mm
(0.001 in.)
(0.311 – 0.312 in.)
Taper (Max.) 0.025 mm
(0.001 in.) Guide Bore 7.950 – 7.976 mm
Oversize Limit 1.016 mm (0.313 – 0.314 in.)
(0.040 in.) Stem to Guide Clearance 0.0254 – 0.0762 mm
Lifter Bore Diameter 22.99 – 23.01 mm (0.001 – 0.003 in.)
(0.9051 – 0.9059 in.) Service Limit (rocking 0.4318 mm
method)
Distributor Drive Bushing
(0.017 in.)
(Press Fit)
Bushing to Bore 0.0127 – 0.3556 mm
Interference
(0.0005 – 0.0140 in.)
Shaft to Bushing 0.0178 – 0.0686 mm
Clearance
(0.0007 – 0.0027 in.)

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 9 - 130 5.2L ENGINE DN
SPECIFICATIONS (Continued)

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

VALVE SPRINGS OIL PUMP

Free Length 49.962 mm Clearance over Rotors 0.0381 mm

(1.967 in.) (Max.)
(0.0015 in.)
Spring Tension
valve closed 378 N @ 41.66 mm Inner Rotor Thickness 20.955 mm
(Min.)
(85 lbs. @ 1.64 in.)
(0.825 in.)
valve open 890 N @ 30.89 mm
(200 lbs. @ 1.212 in.) Outer Rotor Clearance 0.3556 mm
(Max.)
Number of Coils 6.5
(0.014 in.)
Installed Height 41.66 mm
Outer Rotor Diameter 62.7126 mm
(1.64 in.) (Min.)
Wire Diameter 4.50 mm (2.469 in.)
(0.177 in.) Outer Rotor Thickness 20.955 mm
(Min.)
HYDRAULIC TAPPETS
(0.825 in.)
Body Diameter 22.949 – 22.962 mm
Tip Clearance between
(0.9035 – 0.9040 in.) Rotors
Clearance (to bore) 0.0279 – 0.0610 mm (Max.) 0.2032 mm
(0.0011 – 0.0024 in.) (0.008 in.)

Dry Lash 1.524 – 5.334 mm PISTONS

(0.060 – 0.210 in.) Clearance at Top of Skirt 0.013 – 0.038 mm
Push Rod Length 175.64 – 176.15 mm (0.0005 – 0.0015 in.)
(6.915 – 6.935 in.) Land Clearance (Diam.) 0.635 – 1.016 mm
OIL PRESSURE (0.025 – 0.040 in.)

Curb Idle (Min.*) 41.4 kPa (6 psi) Piston Length 86.360 mm (3.40 in.)
@ 3000 rpm 207 – 552 kPa Piston Ring Groove
(30 – 80 psi) Depth
Oil Pressure Bypass Groove #1&2 4.572 – 4.826 mm
Valve (0.180 – 0.190 in.)
Setting 62 – 103 kPa Groove #3 3.810 – 4.064 mm
(9 – 15 psi) (0.150 – 0.160 in.)
Switch Actuating 34.5 – 48.3 kPa Weight 592.6 – 596.6 grams
Pressure
(20.90 – 21.04 oz.)
(5 – 7 psi)

* If oil pressure is zero at curb idle, DO NOT RUN

ENGINE.

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 DN 5.2L ENGINE 9 - 131
SPECIFICATIONS (Continued)

DESCRIPTION SPECIFICATION OVERSIZE AND UNDERSIZE ENGINE

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
U/S Rod/ R or M R-1-4 Milled flat on
(0.9841 – 0.9843 in.) ect. No.8
End Play NONE .0254 Main (indicating crankshaft
mm No. 1
Length 75.946 – 76.454 mm
(0.001 Journal and 4 counterweight.
(2.990 – 3.010 in.) in.) connecting
PISTON RINGS rod journal)
and/or
Ring Gap M-2-3 ect.
Compression Rings 0.254 – 0.508 mm (indicating
(0.010 – 0.020 in.) No. 2
Oil Control (Steel Rails) 0.254 – 1.270 mm and 3 main
(0.010 – 0.050 in.) bearing
journal)
Ring Side Clearance
Compression Rings 0.038 – 0.076 mm O/S Hydraulic l Diamond-
shaped
(0.0015 – 0.0030 in.)
.2032 Tappets stamp top pad
Oil Ring (Steel Rails) 0.06 – 0.21 mm mm -
(0.002 – 0.008 in.) (.008 in.) front of engine
Ring Width and flat
Compression rings 1.971 – 1.989 mm ground

(0.0776 – 0.0783 in.) on outside

Oil Ring (Steel Rails) – 3.848 – 3.975 mm surface of

Max. each

(0.1515 – 0.1565 in.) O/S tappet

bore.
VALVE TIMING
O/S Valve X Milled pad
Exhaust Valve .127 mm Stems adjacent to
Closes (ATDC) 21° two
Opens (BBDC) 60° (.005 in.) tapped holes
Duration 264° (3/8 in.) on
each
Intake Valve end of
Closes (ATDC) 61° cylinder
Opens (BBDC) 10° head.
Duration 250°

Valve Overlap 31°

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 9 - 132 5.2L ENGINE DN
SPECIFICATIONS (Continued)

TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. In.

TORQUE CHART 5.2L ENGINE
Lbs. Lbs.
Rear Insulator to 68 50 —
DESCRIPTION N·m Ft. In. Transmission—
Lbs. Lbs. Bolts (4WD)
Camshaft Sprocket—Bolt 68 50 — Rear Insulator Bracket—Bolts 68 50 —
Camshaft Thrust Plate—Bolts 24 — 210
(4WD Automatic)
Chain Case Cover—Bolts 41 30 —
Rear Support Plate to 41 30 —
Connecting Rod Cap—Bolts 61 45 — Transfer Case
Main Bearing Cap—Bolts 115 85 — —Bolts
Crankshaft Pulley—Bolts 24 — 210 Rocker Arm—Bolts 28 21 —
Cylinder Head—Bolts Spark Plugs 41 30 —
Step 1 68 50 — Starter Motor—Mounting 68 50 —
Step 2 143 105 — Bolts
Cylinder Head Cover—Bolts 11 — 95 Thermostat Housing—Bolts 25 — 225
Engine Support Bracket to 41 30 — Throttle Body—Bolts 23 — 200
Block— Torque Converter Drive 31 — 270
Bolts (4WD) Plate—Bolts
Exhaust Manifold to Cylinder 34 25 — Transfer Case to Insulator 204 150 —
Head— Mounting
Bolts/Nuts Plate—Nuts
Flywheel—Bolts 75 55 — Transmission Support 68 50 —
Bracket—
Front Insulator—Through 95 70 —
bolt/nut Bolts (2WD)
Front Insulator to Support Vibration Damper—Bolt 183 135 —
Bracket— Water Pump to Timing Chain 41 30 —
Stud Nut (4WD) 41 30 — Case
Through Bolt/Nut 102 75 — Cover—Bolts
Front Insulator to Block— 95 70 —
Bolts (2WD) SPECIAL TOOLS
Generator—Mounting Bolts 41 30 —
5.2L ENGINE
Intake Manifold—Bolts Refer to Procedure
Oil Pan—Bolts 24 — 215
Oil Pan—Drain Plug 34 25 —
Oil Pump—Mounting Bolts 41 30 —
Oil Pump Cover—Bolts 11 — 95
Rear Insulator to Bracket— 68 50 —
Through
Bolt (2WD)
Rear Insulator to 41 30 —
Crossmember Oil Pressure Gauge C-3292
Support Bracket—Nut (2WD)
Rear Insulator to 68 50 —
Crossmember—
Nuts (4WD)

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 DN 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

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 9 - 134 5.2L ENGINE DN
SPECIAL TOOLS (Continued)

Distributor Bushing Puller C-3052 Crankshaft Main Bearing Remover C-3059

Distributor Bushing Driver/Burnisher C-3053 Cylinder Bore Gauge C-119

Piston Ring Compressor C-385

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 DN 5.9L ENGINE 9 - 135

5.9L ENGINE

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION ENGINE REAR SUPPORT . . . . . . . . . . . . . . . . . 160

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . 161
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . 136 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 163
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 139 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 165
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 139 CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 165
CYLINDER HEAD COVER GASKET . . . . . . . . . . 140 ROCKER ARMS AND PUSH RODS . . . . . . . . . . 166
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 140 VALVE SPRING AND STEM SEAL
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 140 REPLACEMENT-IN VEHICLE . . . . . . . . . . . . . 166
ENGINE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . 140 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 167
CRANKSHAFT OIL SEALS . . . . . . . . . . . . . . . . . 140 VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 167
PISTON AND CONNECTING ROD . . . . . . . . . . . 140 HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 168
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 141 VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . 168
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 141 TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . 169
DIAGNOSIS AND TESTING TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 170
ENGINE DIAGNOSIS—INTRODUCTION. . . . . . . 141 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
SERVICE DIAGNOSIS—GASOLINE ENGINES . . 142 CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . 172
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . 145 DISTRIBUTOR DRIVE SHAFT BUSHING . . . . . . 172
CYLINDER COMPRESSION PRESSURE TEST . 145 CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 174
CYLINDER HEAD GASKET FAILURE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . 146 PISTON AND CONNECTING ROD ASSEMBLY . . 175
CYLINDER COMBUSTION PRESSURE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 176
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 146 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
INSPECTION (ENGINE OIL LEAKS IN CRANKSHAFT OIL SEAL—FRONT. . . . . . . . . . . 178
GENERAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 CRANKSHAFT OIL SEALS—REAR. . . . . . . . . . . 179
REAR SEAL AREA LEAKS—INSPECTION . . . . . 147 ENGINE CORE OIL AND CAMSHAFT PLUGS . . 180
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 148 DISASSEMBLY AND ASSEMBLY
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . 148 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
SERVICE PROCEDURES CLEANING AND INSPECTION
FORM-IN-PLACE GASKETS . . . . . . . . . . . . . . . . 149 CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 182
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . 149 CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . 182
ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 PISTON AND CONNECTING ROD ASSEMBLY . . 182
REPAIR DAMAGED OR WORN THREADS . . . . . 151 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
CYLINDER BORE—HONING . . . . . . . . . . . . . . . 152 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
HYDROSTATIC LOCK. . . . . . . . . . . . . . . . . . . . . 152 CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . 185
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . 153 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 185
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 153 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 185
MEASURING TIMING CHAIN STRETCH . . . . . . . 155 SPECIFICATIONS
PISTONS—FITTING . . . . . . . . . . . . . . . . . . . . . . 156 5.9L ENGINE SPECIFICATIONS . . . . . . . . . . . . . 185
PISTON RINGS—FITTING . . . . . . . . . . . . . . . . . 156 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 189
CONNECTING ROD BEARINGS—FITTING. . . . . 157 SPECIAL TOOLS
CRANKSHAFT MAIN BEARINGS—FITTING . . . . 157 5.9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
REMOVAL AND INSTALLATION
ENGINE FRONT MOUNTS . . . . . . . . . . . . . . . . . 158

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 9 - 136 5.9L ENGINE DN

DESCRIPTION AND OPERATION ENGINE LUBRICATION SYSTEM

ENGINE DESCRIPTION
A gear-type positive displacement pump (Fig. 3) is
DESCRIPTION mounted at the underside of the rear main bearing
The 5.9 Liter (360 CID) eight-cylinder engine is a cap. The pump uses a pick-up tube and screen
V-Type lightweight, single cam, overhead valve assembly to gather engine oil from the oil pan.
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
The engine lubrication system consists of a rotor
type oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1).

Fig. 3 Positive Displacement Oil Pump—Typical

1 – INNER ROTOR AND SHAFT
2 – BODY
3 – DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 – COTTER PIN
5 – RETAINER CAP
6 – SPRING
7 – RELIEF VALVE
8 – LARGE CHAMFERED EDGE
9 – BOLT
10 – COVER
11 – OUTER ROTOR
Fig. 1 Firing Order
The engine serial number is stamped into a
machined pad located on the left, front corner of the OPERATION
cylinder block. When component part replacement is The pump draws oil through the screen and inlet
necessary, use the engine type and serial number for tube from the sump at the rear of the oil pan. The oil
reference (Fig. 2). is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery that
channels the oil up to the main gallery, which
extends the entire length on the right side of the
block. The oil then goes down to the No. 1 main bear-
ing, back up to the left side of the block, and into the
oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Fig. 2 Engine Identification Number Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod
rotates. This oil throwoff lubricates the camshaft
lobes, distributor drive gear, cylinder walls, and pis-
ton pins.

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 DN 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. The front rocker arm lubricates the valve train components.
camshaft bearing journal passes oil through the cam- The oil then passes down through the push rod guide
shaft sprocket to the timing chain. Oil drains back to holes and the oil drain-back passages in the cylinder
the oil pan under the No. 1 main bearing cap. head, past the valve tappet area, and then returns to
The oil supply for the rocker arms and bridged the oil pan.
pivot assemblies is provided by the hydraulic valve

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 9 - 138 5.9L ENGINE DN
DESCRIPTION AND OPERATION (Continued)

Fig. 4 Oil Lubrication System

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 DN 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 – DRIP OILING FOR VALVE TIP 18 –
OIL TO FILTER
6 – CYLINDER HEAD BOSS 19 –
OIL FROM FILTER TO SYSTEM
7 – TO MAIN BEARINGS 20 –
PASSAGE TO CAMSHAFT REAR BEARING
8 – TO CAMSHAFT BEARINGS 21 –
RIGHT OIL GALLERY
9 – ROCKER ARM 22 –
PLUG
10 – HOLLOW PUSH ROD 23 –
OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT
11 – TAPPET 24 –
OIL SUPPLY VIA HOLLOW PUSH ROD SUPPLY IS FROM
12 – TO CONNECTING ROD BEARINGS OIL GALLERY METERED THROUGH HYDRAULIC TAPPET
13 – OIL INTAKE 25 – OIL SUPPLY FROM HOLLOW PUSH ROD

EXHAUST MANIFOLD must be used when sealing the gaskets to ensure

that excess sealant does not enter the intake runners
DESCRIPTION causing a restriction. Whenever the intake manifold
The exhaust manifolds are constructed of cast iron is removed inspect the plenum pan for evidence of
and are LOG type with balanced flow (Fig. 5). One excess oil buildup, this condition indicates that the
exhaust manifold is attached to each cylinder head. plenum pan gasket is leaking.

Fig. 5 Exhaust Manifolds—V-8 Gas Engines Typical

1 – EXHAUST MANIFOLD (LEFT)
2 – BOLTS & WASHERS
3 – NUTS & WASHERS
4 – EXHAUST MANIFOLD (RIGHT)
5 – BOLTS & WASHERS Fig. 6 Intake Manifold and Throttle Body—V-8 Gas
Engines Typical
1 – FUEL RAIL ASSEMBLY
OPERATION 2 – FUEL RAIL MOUNTING BOLTS
The exhaust manifolds collect the engine exhaust 3 – FUEL RAIL CONNECTING HOSES
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipes attached to the
manifolds. OPERATION
The intake manifold, meters and delivers air to the
INTAKE MANIFOLD combustion chambers allowing the fuel delivered by
the fuel injectors to ignite, thus producing power.
DESCRIPTION
The aluminum intake manifold (Fig. 6) is a single
plane design with equal length runners and uses a
separate plenum, therefore the manifold does have a
plenum gasket. It also uses separate flange gaskets
and front and rear cross-over gaskets. Extreme care

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 9 - 140 5.9L ENGINE DN
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
The cylinder head cover gasket is a steel-backed to the correct ratio for ignition. The valves located in
silicone gasket, designed for long life usage (Fig. 7). the cylinder head open and close to either allow clean
air into the combustion chamber or to allow the
exhaust gases out, depending on the stroke of the
engine.

VALVES AND VALVE SPRINGS

DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 48.768 mm (1.92 inches) in
diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch)
Fig. 7 Cylinder Head Cover Gasket V-8 Gas Engines wafer interia welded to the tip for durability. These
1 – CYLINDER HEAD COVER GASKET valves are not splayed.

OPERATION ENGINE OIL PAN

The steel-backed silicone gasket is designed to seal
the cylinder head cover for long periods of time
DESCRIPTION
The stamped steel engine oil pan is located at the
through extensive heat and cold, without failure. The
bottom of the engine, and contains a drain plug for
gasket is designed to be reusable.
draining the engine oil.
CYLINDER HEAD OPERATION
The oil pan holds the engine oil and seals and pro-
DESCRIPTION
tects the engine lower components from contami-
The cast iron cylinder heads (Fig. 8) are mounted
nates.
to the cylinder block using ten bolts. The spark plugs
are located in the peak of the wedge between the
valves.
CRANKSHAFT OIL SEALS
DESCRIPTION
The crankshaft rear seal is a two piece viton seal.
The crankshaft front seal is a one piece viton seal
with a steel housing. The front seal is located in the
engine front cover. One part of the two piece rear
seal is located in a slot in the number five (5) crank-
shaft main bore, the second part of the two piece seal
is located in the number five (5) main bearing cap.

OPERATION
The crankshaft seals prevent oil from leaking from
around the crankshaft, either from the rear of the
engine or from the engine front cover.

Fig. 8 Cylinder Head Assembly—V-8 Gas Engines

PISTON AND CONNECTING ROD
1 – EXHAUST VALVE
2 – SPARK PLUGS
DESCRIPTION
3 – EXHAUST VALVES The pistons are made of aluminum and have three
4 – SPARK PLUGS ring grooves, the top two grooves are for the compres-
5 – EXHAUST VALVE sion rings and the bottom groove is for the oil control
6 – INTAKE VALVES ring. The connecting rods are forged steel and are
7 – INTAKE VALVES coined prior to heat treat. The piston pins are press
fit.

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 DN 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. 9). There
are five main bearings. Number three main bearing
is flanged, this flange controls crankshaft thrust.

Fig. 10 Crankshaft with Journal Size Identification

DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS—INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
Fig. 9 Main Bearing Orientation (e.g., engine idles rough and stalls).
Refer to the Service Diagnosis—Mechanical Chart
OPERATION
and the Service Diagnosis—Performance Chart, for
The main bearings encircle the crankshaft main
possible causes and corrections of malfunctions. Refer
bearing journals, this aligns the crankshaft to the
to FUEL SYSTEM for the fuel system diagnosis.
centerline of the engine and allows the crankshaft to
Additional tests and diagnostic procedures may be
turn without wobbling or shaking therefore eliminat-
necessary for specific engine malfunctions that can-
ing vibration. The main bearings are available in
not be isolated with the Service Diagnosis charts.
standard and undersizes.
Information concerning additional tests and diagno-
sis is provided within the following:
CRANKSHAFT • Cylinder Compression Pressure Test
• Cylinder Combustion Pressure Leakage Test
DESCRIPTION • Cylinder Head Gasket Failure Diagnosis
The crankshaft is of a cast nodular steel splayed • Intake Manifold Leakage Diagnosis
type design, with five main bearing journals. The • Lash Adjuster (Tappet) Noise Diagnosis
crankshaft is located at the bottom of the engine • Engine Oil Leak Inspection
block and is held in place with five main bearing
caps. The number 3 counterweight is the location for
journal size identification (Fig. 10).

OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.

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 9 - 142 5.9L ENGINE DN
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. Refer to Group 8C, Charging Systems, for
correct procedures.

2. Corroded or loose battery 2. Clean/tighten suspect battery/starter connections

connections
3. Faulty starter or related circuit(s) 3. Check starting system. Refer to Group 8B,
Starting Systems, for correct diagnostics/procedures
4. Seized accessory drive 4. Remove accessory drive belt and attempt to start
component engine. If engine starts, repair/replace seized
component.
5. Engine internal mechanical 5. Refer to Group 9, Engine, for correct diagnostics/
failure or hydro-static lock procedures

ENGINE CRANKS 1. No spark 1. Check for spark. Refer to Group 8D, Ignition
BUT WILL NOT System, for correct procedures.
START
2. No fuel 2. Perform fuel pressure test, and if necessary,
inspect fuel injector(s) and driver circuits. Refer to
Group 14, Fuel System, for correct procedures.
3. Low or no engine compression 3. Perform cylinder compression pressure test. Refer
to Group 9, Engine, for correct procedures.

ENGINE LOSS OF 1. Worn or burned distributor rotor 1. Install new distributor rotor
POWER
2. Worn distributor shaft 2. Remove and repair distributor (Refer to Group 8D,
Ignition System
3. Worn or incorrect gapped spark 3. Clean plugs and set gap. (Refer to Group 8D,
plugs Ignition System)
4. Dirt or water in fuel system 4. Clean system and replace fuel filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression
9. Burned, warped, or pitted valves 9. Install/Reface valves as necessary
10. Plugged or restricted exhaust 10. Install new parts as necessary
system
11. Faulty ignition cables 11. Replace any cracked or shorted cables
12. Faulty ignition coil 12. Test and replace, as necessary (Refer to Group
8D, Ignition System)

ENGINE STALLS 1. Carbon build-up on throttle plate 1. Remove throttle body and de-carbon. (Refer to
OR ROUGH IDLE Group 14 for correct procedures)
2. Engine idle speed too low 2. Check Idle Air Control circuit. (Refer to Group 14,
Fuel System)

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 DN 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. Install new distributor rotor
5. Spark plug cables defective or 5. Check for correct firing order or replace spark plug
crossed cables. (Refer to Group 8D, Ignition System for
correct procedures.)
6. Faulty coil 6. Test and replace, if necessary (Refer to group 8D,
Ignition System)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket and vacuum hoses.
Replace if necessary
8. EGR valve leaking or stuck open 8. Test and replace, if necessary (Refer to group 25,
Emission Control Systems)

ENGINE MISSES 1. Worn or incorrectly gapped spark 1. Replace spark plugs or clean and set gap. (Refer
ON plugs to group 8D, Ignition System)
ACCELERATION
2. Spark plug cables defective or 2. Replace or rewire secondary ignition cables. Refer
crossed to Group 8D, Ignition System
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary (refer to group 8D,
Ignition System)

MECHANICAL DIAGNOSIS CHART—GASOLINE ENGINES

CONDITION POSSIBLE CAUSES CORRECTION

NOISY VALVES/ 1. High or low oil level 1. Check for correct oil level. Adjust oil level by draining or adding
LIFTERS in crankcase as needed
2. Thin or diluted oil 2. Change oil (Refer to Engine Oil Service in this group)
3. Low oil pressure 3. Check engine oil level. If ok, Perform oil pressure test. Refer to
this group for engine oil pressure test/specifications
4. Dirt in tappets/lash 4. Clean/replace hydraulic tappets/lash adjusters
adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms and replace worn arms as
needed
7. Worn tappets/lash 7. Install new hydraulic tappets/lash adjusters
adjusters
8. Worn valve guides 8. Inspect all valve guides and replace as necessary
9. Excessive runout of 9. Grind valves and seats
valve seats or valve
faces

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 9 - 144 5.9L ENGINE DN
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. Thin or diluted oil 3. Change oil to correct viscosity. Refer to this group for correct
procedure/engine oil specifications
4. Excessive connecting Measure bearings for correct clearance with plasti-gage. Repair
rod bearing clearance as necessary
5. Connecting rod 5. Replace crankshaft or grind journals
journal out of round
6. Misaligned 6. Replace bent connecting rods
connecting rods

MAIN BEARING 1. Insufficient oil supply 1. Check engine oil level. (Refer to group 0, Lubrication and
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. Thin or diluted oil 3. Change oil to correct viscosity. Refer to this group for correct
procedure/engine oil specifications
4. Excessive main 4. Measure bearings for correct clearance. Repair as necessary
bearing clearance
5. Excessive end play 5. Check crankshaft thrust bearing for excessive wear on flanges
6. Crankshaft main 6. Grind journals or replace crankshaft
journal out of round or
worn
7. Loose flywheel or 7. Inspect crankshaft, flexplate/flywheel and bolts for damage.
torque converter Tighten to correct torque

LOW OIL 1. Low oil level 1. Check oil level and fill if necessary
PRESSURE
2. Faulty oil pressure 2. Install new sending unit
sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace worn gears or oil pump assy
5. Thin or diluted oil 5. Change oil to correct viscosity. Refer to this group for correct
procedure/engine oil specifications
6. Excessive bearing 6. Measure bearings for correct clearance
clearance
7. Oil pump relief valve 7. Remove valve to inspect, clean and reinstall
stuck
8. Oil pump suction 8. Inspect suction tube and clean or replace if necessary
tube loose, broken, bent
or clogged
9. Oil pump cover 9. Install new oil pump
warped or cracked

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 DN 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. Replace seal
crankshaft oil seal
leaking
4. Leaking oil gallery 4. Remove and reseal threaded plug. Replace cup style plug
plug or cup plug
5. Leaking intake 5. Replace gaskets
manifold cross-over
gaskets

EXCESSIVE OIL 1. PCV System 1. Refer to group 25, Emission Control System for correct
CONSUMPTION malfunction operation
OR SPARK
PLUGS OIL
FOULED
2. Intake manifold 2. Replace plenum
plenum pan gasket pan gasket
failure
3. Defective valve 3. Replace seals
stem seal(s)
4. Worn or broken 4. Hone cylinder bores. Install new rings
piston rings
5. Scuffed pistons/ 5. Hone cylinder bores and replace pistons as required
cylinder walls
6. Carbon in oil control 6. Remove rings and de-carbon piston
ring groove
7. Worn valve guides 6. Repair as
necessary
8. Piston rings fitted 8. Remove rings and
too tightly in grooves check ring end gap
and side clearance.
Replace if necessary

INTAKE MANIFOLD LEAKAGE DIAGNOSIS (1) Start the engine.

An intake manifold air leak is characterized by (2) Spray a small stream of water at the suspected
lower than normal manifold vacuum. Also, one or leak area.
more cylinders may not be functioning. (3) If a change in RPMs, the area of the suspected
leak has been found.
WARNING: USE EXTREME CAUTION WHEN THE (4) Repair as required.
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR CYLINDER COMPRESSION PRESSURE TEST
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN. The results of a cylinder compression pressure test
DO NOT WEAR LOOSE CLOTHING. can be utilized to diagnose several engine malfunc-
tions.

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 9 - 146 5.9L ENGINE DN
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
not be valid for diagnosis purposes. PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
(1) Clean the spark plug recesses with compressed SIVE PRESSURE BUILT UP, BY CONTINUOUS
air. ENGINE OPERATION, MUST BE RELEASED TO A
(2) Remove the spark plugs. SAFE PRESSURE POINT. NEVER PERMIT PRES-
(3) Secure the throttle in the wide-open position. SURE TO EXCEED 138 kPa (20 psi).
(4) Disconnect the ignition coil.
(5) Insert a compression pressure gauge and rotate Install Cooling System Tester 7700 or equivalent to
the engine with the engine starter motor for three pressure cap neck. Start the engine and observe the
revolutions. tester’s pressure gauge. If gauge pulsates with every
(6) Record the compression pressure on the third power stroke of a cylinder a combustion pressure
revolution. Continue the test for the remaining cylin- leak is evident.
ders.
Refer to Engine Specifications for the correct CHEMICAL TEST METHOD
engine compression pressures. Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
CYLINDER HEAD GASKET FAILURE DIAGNOSIS equivalent. Perform test following the procedures
A cylinder head gasket leak can be located between supplied with the tool kit.
adjacent cylinders or between a cylinder and the
adjacent water jacket. CYLINDER COMBUSTION PRESSURE LEAKAGE
• Possible indications of the cylinder head gasket TEST
leaking between adjacent cylinders are: The combustion pressure leakage test provides an
• Loss of engine power accurate means for determining engine condition.
• Engine misfiring Combustion pressure leakage testing will detect:
• Poor fuel economy • Exhaust and intake valve leaks (improper seat-
• Possible indications of the cylinder head gasket ing)
leaking between a cylinder and an adjacent water • Leaks between adjacent cylinders or into water
jacket are: jacket
• Engine overheating • Any causes for combustion/compression pressure
• Loss of coolant loss
• Excessive steam (white smoke) emitting from
exhaust WARNING: DO NOT REMOVE THE RADIATOR CAP
• Coolant foaming WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM HOT COOLANT CAN
CYLINDER-TO-CYLINDER LEAKAGE TEST OCCUR.
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce- Check the coolant level and fill as required. DO
dures in Cylinder Compression Pressure Test in this NOT install the radiator cap.
section. An engine cylinder head gasket leaking Start and operate the engine until it attains nor-
between adjacent cylinders will result in approxi- mal operating temperature, then turn OFF the
mately a 50–70% reduction in compression pressure. engine.
Remove the spark plugs.
CYLINDER-TO-WATER JACKET LEAKAGE TEST Remove the oil filler cap.
Remove the air cleaner.
WARNING: USE EXTREME CAUTION WHEN THE Calibrate the tester according to the manufactur-
ENGINE IS OPERATING WITH COOLANT PRES- er’s instructions. The shop air source for testing
SURE CAP REMOVED. should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
VISUAL TEST METHOD Perform the test procedure on each cylinder accord-
With the engine cool, remove the coolant pressure ing to the tester manufacturer’s instructions. While
cap. Start the engine and allow it to warm up until testing, listen for pressurized air escaping through
thermostat opens. the throttle body, tailpipe or oil filler cap opening.
If a large combustion/compression pressure leak Check for bubbles in the radiator coolant.
exists, bubbles will be visible in the coolant.

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 DN 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). Inspect the
sure, a minimum of 414 kPa (60 psi) should be main- engine for signs of an oil leak by using a black light.
tained in the cylinder.
Refer to the Cylinder Combustion Pressure Leak- REAR SEAL AREA LEAKS—INSPECTION
age Test Diagnosis chart. Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
INSPECTION (ENGINE OIL LEAKS IN GENERAL) engine, a more involved inspection is necessary. The
Begin with a through visual inspection of the following steps should be followed to help pinpoint
engine, particularly at the area of the suspected leak. the source of the leak.
If an oil leak source is not readily identifiable, the If the leakage occurs at the crankshaft rear oil seal
following steps should be followed: area:
(1) Do not clean or degrease the engine at this (1) Disconnect the battery.
time because some solvents may cause rubber to (2) Raise the vehicle.
swell, temporarily stopping the leak. (3) Remove torque converter or clutch housing
(2) Add an oil-soluble dye (use as recommended by cover and inspect rear of block for evidence of oil.
manufacturer). Start the engine and let idle for Use a black light to check for the oil leak:
approximately 15 minutes. Check the oil dipstick to (a) Circular spray pattern generally indicates
be sure the dye is thoroughly mixed as indicated seal leakage or crankshaft damage.
with a bright yellow color under a black light source. (b) Where leakage tends to run straight down,
(3) Using a black light, inspect the entire engine possible causes are a porous block, distributor seal,
for fluorescent dye, particularly at the suspected area camshaft bore cup plugs, oil galley pipe plugs, oil
of oil leak. If the oil leak is found and identified, filter runoff, and main bearing cap to cylinder
repair per service manual instructions. block mating surfaces. See Group 9, Engines, for
(4) If dye is not observed, drive the vehicle at var- proper repair procedures of these items.
ious speeds for approximately 24km (15 miles), and (4) If no leaks are detected, pressurized the crank-
repeat previous step. case as outlined in the section, Inspection (Engine oil
(5) If the oil leak source is not positively identified Leaks in general)
at this time, proceed with the air leak detection test
method as follows: CAUTION: Do not exceed 20.6 kPa (3 psi).
(6) Disconnect the breather cap to air cleaner hose
at the breather cap end. Cap or plug breather cap (5) If the leak is not detected, very slowly turn the
nipple. crankshaft and watch for leakage. If a leak is
(7) Remove the PCV valve from the cylinder head detected between the crankshaft and seal while
cover. Cap or plug the PCV valve grommet. slowly turning the crankshaft, it is possible the
(8) Attach an air hose with pressure gauge and crankshaft seal surface is damaged. The seal area on
regulator to the dipstick tube. the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure. CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
(9) Gradually apply air pressure from 1 psi to 2.5 scratches. The crankshaft seal flange is specially
psi maximum while applying soapy water at the sus- machined to complement the function of the rear oil
pected source. Adjust the regulator to the suitable seal.
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is (6) For bubbles that remain steady with shaft
detected and identified, repair per service manual rotation, no further inspection can be done until dis-
procedures. assembled. Refer to the service Diagnosis—Mechani-
(10) If the leakage occurs at the rear oil seal area, cal, under the Oil Leak row, for components
refer to the section, Inspection for Rear Seal Area inspections on possible causes and corrections.
Leak. (7) After the oil leak root cause and appropriate
(11) If no leaks are detected, turn off the air sup- corrective action have been identified, Refer to Group
ply and remove the air hose and all plugs and caps. 9, Engines—Crankshaft Rear Oil Seals, for proper
Install the PCV valve and breather cap hose. Proceed replacement procedures.
to next step.

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 9 - 148 5.9L ENGINE DN
DIAGNOSIS AND TESTING (Continued)

HYDRAULIC TAPPETS plunger partially sticking in the tappet body cylinder.

Before disassembling any part of the engine to cor- The tappet should be replaced. A heavy click is
rect tappet noise, check the oil pressure. If vehicle caused by a tappet check valve not seating, or by for-
has no oil pressure gauge, install a reliable gauge at eign particles wedged between the plunger and the
the pressure sending-unit. The pressure should be tappet body. This will cause the plunger to stick in
between 207-552 kPa (30-80 psi) at 3,000 RPM. the down position. This heavy click will be accompa-
Check the oil level after the engine reaches normal nied by excessive clearance between the valve stem
operating temperature. Allow 5 minutes to stabilize and rocker arm as valve closes. In either case, tappet
oil level, check dipstick. The oil level in the pan assembly should be removed for inspection and clean-
should never be above the FULL mark or below the ing.
ADD OIL mark on dipstick. Either of these two con- (4) The valve train generates a noise very much
ditions could be responsible for noisy tappets. like a light tappet noise during normal operation.
Care must be taken to ensure that tappets are mak-
OIL LEVEL ing the noise. If more than one tappet seems to be
noisy, it’s probably not the tappets.
HIGH
If oil level is above the FULL mark, it is possible LEAK-DOWN TEST
for the connecting rods to dip into the oil. With the After cleaning and inspection, test each tappet for
engine running, this condition could create foam in specified leak-down rate tolerance to ensure zero-lash
the oil pan. Foam in oil pan would be fed to the operation (Fig. 11).
hydraulic tappets by the oil pump causing them to Swing the weighted arm of the hydraulic valve tap-
lose length and allow valves to seat noisily. pet tester away from the ram of the Universal Leak-
Down Tester.
LOW (1) Place a 7.925-7.950 mm (0.312-0.313 inch)
Low oil level may allow oil pump to take in air. diameter ball bearing on the plunger cap of the tap-
When air is fed to the tappets, they lose length, pet.
which allows valves to seat noisily. Any leaks on (2) Lift the ram and position the tappet (with the
intake side of oil pump through which air can be ball bearing) inside the tester cup.
drawn will create the same tappet action. Check the (3) Lower the ram, then adjust the nose of the ram
lubrication system from the intake strainer to the until it contacts the ball bearing. DO NOT tighten
pump cover, including the relief valve retainer cap. the hex nut on the ram.
When tappet noise is due to aeration, it may be (4) Fill the tester cup with hydraulic valve tappet
intermittent or constant, and usually more than one test oil until the tappet is completely submerged.
tappet will be noisy. When oil level and leaks have (5) Swing the weighted arm onto the push rod and
been corrected, operate the engine at fast idle. Run pump the tappet plunger up and down to remove air.
engine for a sufficient time to allow all of the air When the air bubbles cease, swing the weighted arm
inside the tappets to be bled out. away and allow the plunger to rise to the normal
position.
TAPPET NOISE DIAGNOSIS (6) Adjust the nose of the ram to align the pointer
(1) To determine source of tappet noise, operate with the SET mark on the scale of the tester and
engine at idle with cylinder head covers removed. tighten the hex nut.
(2) Feel each valve spring or rocker arm to detect (7) Slowly swing the weighted arm onto the push
noisy tappet. The noisy tappet will cause the affected rod.
spring and/or rocker arm to vibrate or feel rough in (8) Rotate the cup by turning the handle at the
operation. base of the tester clockwise one revolution every 2
seconds.
NOTE: Worn valve guides or cocked springs are (9) Observe the leak-down time interval from the
sometimes mistaken for noisy tappets. If such is instant the pointer aligns with the START mark on
the case, noise may be dampened by applying side the scale until the pointer aligns with the 0.125
thrust on the valve spring. If noise is not apprecia- mark. A normally functioning tappet will require
bly reduced, it can be assumed the noise is in the 20-110 seconds to leak-down. Discard tappets with
tappet. Inspect the rocker arm push rod sockets leak-down time interval not within this specification.
and push rod ends for wear.
ENGINE OIL PRESSURE
(3) Valve tappet noise ranges from light noise to a (1) Remove oil pressure sending unit.
heavy click. A light noise is usually caused by exces-
sive leak-down around the unit plunger, or by the

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 DN 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. DO NOT use
on flexible metal flanges.

SURFACE PREPARATION
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some
instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
Scrape or wire brush all gasket surfaces to remove
Fig. 11 Leak-Down Tester all loose material. Inspect stamped parts to ensure
1 – POINTER
gasket rails are flat. Flatten rails with a hammer on
2 – WEIGHTED ARM
a flat plate, if required. Gasket surfaces must be free
3 – RAM
4 – CUP
of oil and dirt. Make sure the old gasket material is
5 – HANDLE removed from blind attaching holes.
6 – PUSH ROD
GASKET APPLICATION
Assembling parts using a form-in-place gasket
(2) Install Oil Pressure Line and Gauge Tool
requires care.
C-3292. Start engine and record pressure. Refer to
Mopar Silicone Rubber Adhesive Sealant should be
Oil Pressure in Engine Specifications for the proper
applied in a continuous bead approximately 3 mm
pressures.
(0.12 inch) in diameter. All mounting holes must be
circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4
SERVICE PROCEDURES inch) drop is placed in the center of the gasket con-
tact area. Uncured sealant may be removed with a
FORM-IN-PLACE GASKETS shop towel. Components should be torqued in place
There are several places where form-in-place gas- while the sealant is still wet to the touch (within 10
kets are used on the engine. DO NOT use form-in- minutes). The use of a locating dowel is recom-
place gasket material unless specified. Care mended during assembly to prevent smearing the
must be taken when applying form-in-place gaskets. material off location.
Bead size, continuity and location are of great impor- Mopar Gasket Maker should be applied sparingly
tance. Too thin a bead can result in leakage while too to one gasket surface. The sealant diameter should
much can result in spill-over. A continuous bead of be 1.00 mm (0.04 inch) or less. Be certain the mate-
the proper width is essential to obtain a leak-free rial surrounds each mounting hole. Excess material
joint. can easily be wiped off. Components should be
Two types of form-in-place gasket materials are torqued in place within 15 minutes. The use of a
used in the engine area (Mopar Silicone Rubber locating dowel is recommended during assembly to
Adhesive Sealant and Mopar Gasket Maker). Each prevent smearing the material off location.
have different properties and cannot be used inter-
changeably. ENGINE PERFORMANCE
It is important that the vehicle is operating to its
MOPAR SILICONE RUBBER ADHESIVE SEALANT optimum performance level to maintain fuel economy
Mopar Silicone Rubber Adhesive Sealant, normally and the lowest emission levels. If vehicle is not oper-
black in color, is available in 3 ounce tubes. Moisture ating to these standards, refer to Engine Diagnosis
in the air causes the sealant material to cure. This outlined in this section. The following procedures can
material is normally used on flexible metal flanges. assist in achieving the proper engine diagnosis.
It has a shelf life of a year and will not properly cure (1) Test cranking amperage draw. Refer to Electri-
if over aged. Always inspect the package for the expi- cal Group 8B, Cold Cranking Test.
ration date before use.

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 9 - 150 5.9L ENGINE DN
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.
Tighten to specifications.
(5) Test resistance of spark plug cables. Refer to
Electrical Group 8D, Spark Plug Cables.
(6) Inspect the primary wires. Test coil output volt-
age and primary resistance. Replace parts as neces- Fig. 12 Engine Oil Container Standard Notations
sary. Refer to Electrical Group 8D, for specifications. SAE viscosity grade which indicates the cold-to-hot
(7) Test fuel pump for pressure. Refer to Group 14, temperature viscosity range. When choosing an
Fuel System Specifications. engine oil, consider the range of temperatures the
(8) The air filter elements should be replaced as vehicle will be operated in before the next oil change.
specified in Lubrication and Maintenance, Group 0. Select an engine oil that is best suited to your area’s
(9) Inspect crankcase ventilation system as out particular ambient temperature range and variation
lined in Group 0, Lubrication and Maintenance. For (Fig. 13).
emission controls see Group 25, Emission Controls
for service procedures.
(10) Road test vehicle as a final test.

ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO Fig. 13 Temperature/Engine Oil Viscosity
NOT POLLUTE, DISPOSE OF USED ENGINE OIL Recommendation
PROPERLY. ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
ENGINE OIL SPECIFICATION SERVING is located on the label of an engine oil con-
tainer.
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
OIL LEVEL INDICATOR (DIPSTICK)
lubricant. Engine failure can result.
The engine oil level indicator is located at the right
front of the engine, left of the generator on 5.9L
API SERVICE GRADE CERTIFIED engines (Fig. 14).
In gasoline engines, use an engine oil that is API
Service Grade Certified (Fig. 12). Standard engine oil CRANKCASE OIL LEVEL INSPECTION
identification notations have been adopted to aid in
CAUTION: Do not overfill crankcase with engine oil,
the proper selection of engine oil. The identifying
oil foaming and oil pressure loss can result.
notations are located on the label of engine oil plastic
bottles and the top of engine oil cans. MOPAR only To ensure proper lubrication of an engine, the
provides engine oil that conforms to this certification. engine oil must be maintained at an acceptable level.
The acceptable levels are indicated between the ADD
SAE VISCOSITY and SAFE marks on the engine oil dipstick.
An SAE viscosity grade is used to specify the vis- (1) Position vehicle on level surface.
cosity of engine oil. SAE 10W-30 specifies a multiple
viscosity engine oil. These are specified with a dual

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 DN 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-
flow, disposable type oil filter. DaimlerChrysler Cor-
poration recommends a Mopar or equivalent oil filter
be used.

OIL FILTER REMOVAL

Fig. 14 Engine Oil Dipstick Location—5.9L Engines (1) Position a drain pan under the oil filter.
1 – CYLINDER HEAD COVER (2) Using a suitable oil filter wrench loosen filter.
2 – ENGINE OIL FILL-HOLE CAP (3) Rotate the oil filter counterclockwise to remove
3 – DIPSTICK it from the cylinder block oil filter boss (Fig. 15).
4 – ENGINE OIL FILTER
5 – FILTER BOSS

(2) With engine OFF, allow approximately ten min-

utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Install dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the ADD mark on
dipstick. Fig. 15 Oil Filter Removal—Typical
1 – ENGINE OIL FILTER
ENGINE OIL CHANGE 2 – OIL FILTER WRENCH
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. This infor- (4) When filter separates from adapter nipple, tip
mation can be found in your owner’s manual. gasket end upward to minimize oil spill. Remove fil-
ter from vehicle.
TO CHANGE ENGINE OIL (5) With a wiping cloth, clean the gasket sealing
Run engine until achieving normal operating tem- surface (Fig. 16) of oil and grime.
perature.
(1) Position the vehicle on a level surface and turn OIL FILTER INSTALLATION
engine off. (1) Lightly lubricate oil filter gasket with engine
(2) Hoist and support vehicle on safety stands. oil or chassis grease.
Refer to Hoisting and Jacking Recommendations. (2) Thread filter onto adapter nipple. When gasket
(3) Remove oil fill cap. makes contact with sealing surface, (Fig. 16) hand
(4) Place a suitable drain pan under crankcase tighten filter one full turn, do not over tighten.
drain. (3) Add oil, verify crankcase oil level and start
(5) Remove drain plug from crankcase and allow engine. Inspect for oil leaks.
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and REPAIR DAMAGED OR WORN THREADS
gasket if damaged.
(6) Install drain plug in crankcase. CAUTION: Be sure that the tapped holes maintain
the original center line.

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

CAUTION: DO NOT use engine or transmission oil, CAUTION: DO NOT use the starter motor to rotate
mineral spirits, or kerosene. the crankshaft. Severe damage could occur.

(3) Honing should be done by moving the hone up (5) With all spark plugs removed, rotate the crank-
and down fast enough to get a crosshatch pattern. shaft using a breaker bar and socket.

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 DN 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. valve stem and install valve (Fig. 18). The special
(8) Repair engine or components as necessary to sleeve places the valve at the correct height for
prevent this problem from occurring again. checking with a dial indicator.
(9) Squirt engine oil into the cylinders to lubricate
the walls. This will prevent damage on restart.
(10) Install new spark plugs.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N·m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil.
(15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.
Fig. 18 Positioning Valve with Tool C-3973
VALVE TIMING 1 – VALVE
(1) Turn crankshaft until the No.6 exhaust valve is 2 – SPACER TOOL
closing and No.6 intake valve is opening.
(2) Insert a 6.350 mm (1/4 inch) spacer between
(2) Attach Dial Indicator Tool C-3339 to cylinder
rocker arm pad and stem tip of No.1 intake valve.
head and set it at right angle of valve stem being
Allow spring load to bleed tappet down giving in
measured (Fig. 19).
effect a solid tappet.
(3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as pos-
sible. Zero the indicator.
(4) Rotate the crankshaft clockwise (normal run-
ning direction) until the valve has lifted 0.863 mm
(0.034 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
top dead center. Remove spacer.

CAUTION: DO NOT turn crankshaft any further

clockwise as valve spring might bottom and result
in serious damage.

If reading is not within specified limits:

• Check sprocket index marks.
• Inspect timing chain for wear.
• Check accuracy of DC mark on timing indicator.
Fig. 19 Measuring Valve Guide Wear
1 – VALVE
VALVE SERVICE 2 – SPECIAL TOOL C-3339

VALVE CLEANING
Clean valves thoroughly. Discard burned, warped (3) Move valve to and from the indicator. The total
and cracked valves. dial indicator reading should not exceed 0.432 mm
Remove carbon and varnish deposits from inside of (0.017 inch). Ream the guides for valves with over-
valve guides with a reliable guide cleaner. size stems if dial indicator reading is excessive or if
the stems are scuffed or scored.
VALVE INSPECTION Service valves with oversize stems are available as
Measure valve stems for wear. If wear exceeds shown below.
0.051 mm (0.002 inch), replace the valve. Slowly turn reamer by hand and clean guide thor-
oughly before installing new valve. Ream the valve
guides from standard to 0.381 mm (0.015 inch).

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 9 - 154 5.9L ENGINE DN
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 A SEAT WIDTH– 1.016 - 1.524 mm
(0.316 - 0.317 in.) INTAKE (0.040 - 0.060 in.)
0.381 mm (0.015 in.) 8.331 - 8.357 mm SEAT WIDTH– 1.524 - 2.032 mm
(0.328 - 0.329 in.) EXHAUST (0.060 - 0.080 in.)
B FACE ANGLE
Use a 2 step procedure so the valve guides are (INT. and EXT.) 431⁄4° - 433⁄4°
reamed true in relation to the valve seat:
C SEAT ANGLE
• Step 1—Ream to 0.0763 mm (0.003 inch).
• Step 2—Ream to 0.381 mm (0.015 inch). (INT. and EXT.) 441⁄4° - 443⁄4°
D CONTACT
REFACING VALVES AND VALVE SEATS
SURFACE —
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. 20).

Fig. 21 Intake and Exhaust Valves

1 – MARGIN
2 – VALVE SPRING RETAINER LOCK GROOVE
3 – STEM
Fig. 20 Valve Face and Seat Angles 4 – FACE
1 – CONTACT POINT

(2) Measure the concentricity of valve seat using a

VALVES dial indicator. Total runout should not exceed 0.051
Inspect the remaining margin after the valves are mm (0.002 inch) total indicator reading.
refaced (Fig. 21). Valves with less than 1.190 mm (3) Inspect the valve seat with Prussian blue to
(0.047 inch) margin should be discarded. determine where the valve contacts the seat. To do
VALVE SEATS this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
CAUTION: DO NOT un-shroud valves during valve pressure. If the blue is transferred to the center of
seat refacing (Fig. 22). valve face, contact is satisfactory. If the blue is trans-
ferred to the top edge of valve face, lower valve seat
(1) When refacing valve seats, it is important that
with a 15° stone. If the blue is transferred to bottom
the correct size valve guide pilot be used for reseat-
edge of valve face raise valve seat with a 60° stone.
ing stones. A true and complete surface must be
(4) When seat is properly positioned the width of
obtained.
intake seats should be 1.016-1.524 mm (0.040-0.060

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 DN 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 – SHROUD
sprocket bolt, crankshaft should not be permitted to
inch). The width of the exhaust seats should be move. It may be necessary to block the crankshaft to
1.524-2.032 mm (0.060-0.080 inch). prevent rotation.
(3) Hold a scale with dimensional reading even
VALVE SPRING INSPECTION with the edge of a chain link. With cylinder heads
Whenever valves have been removed for inspection, installed, apply 14 N·m (30 ft. lbs.) torque in the
reconditioning or replacement, valve springs should reverse direction. With the cylinder heads removed,
be tested. As an example the compression length of apply 20 N·m (15 ft. lbs.) torque in the reverse direc-
the spring to be tested is 1-5/16 inch. Turn table of tion. Note the amount of chain movement (Fig. 24).
Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 inch mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 23). Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
meet specifications.
Fig. 24 Measuring Timing Chain Wear and Stretch
MEASURING TIMING CHAIN STRETCH 1 – TORQUE WRENCH
2 – 3.175 MM
NOTE: To access timing chain Refer to Timing (0.125 IN.)
Chain Cover in Removal and Installation Section.
(4) Install a new timing chain, if its movement
(1) Place a scale next to the timing chain so that exceeds 3.175 mm (1/8 inch).
any movement of the chain may be measured. (5) If chain is not satisfactory, remove camshaft
(2) Place a torque wrench and socket over cam- sprocket attaching bolt and remove timing chain with
shaft sprocket attaching bolt. Apply torque in the crankshaft and camshaft sprockets.
direction of crankshaft rotation to take up slack; 41 (6) Place both camshaft sprocket and crankshaft
N·m (30 ft. lbs.) torque with cylinder head installed sprocket on the bench with timing marks on exact
or 20 N·m (15 ft. lbs.) torque with cylinder head imaginary center line through both camshaft and
removed. With a torque applied to the camshaft crankshaft bores.

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 9 - 156 5.9L ENGINE DN
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).
(10) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 25).

Fig. 26 Piston Measurements

1 – 49.53 mm
Fig. 25 Alignment of Timing Marks (1.95 IN.)
1 – TIMING MARKS
ring gap should be between 0.508-0.762 mm (0.020-
(11) Install the camshaft bolt. Tighten the bolt to 0.030 inch). The oil ring gap should be 0.254-1.270
47 N·m (35 ft. lbs.) torque. mm (0.010-0.050 inch).
(12) Check camshaft end play. The end play should (c) Rings with insufficient end gap may be prop-
be 0.051-0.152 mm (0.002-0.006 inch) with a new erly filed to the correct dimension. Rings with
thrust plate and up to 0.254 mm (0.010 inch) with a excess gaps should not be used.
used thrust plate. If not within these limits install a (2) Install rings and confirm ring side clearance:
new thrust plate. (a) Install oil rings being careful not to nick or
scratch the piston. Install the oil control rings
PISTONS—FITTING according to instructions in the package. It is not
Piston and cylinder wall must be clean and dry. necessary to use a tool to install the upper and
Specified clearance between the piston and the cylin- lower rails. Insert oil rail spacer first, then side
der wall is 0.013-0.038 mm (0.0005-0.0015 inch) at rails.
21°C (70°F). (b) Install the second compression rings using
Piston diameter should be measured at the top of Installation Tool C-4184. The compression rings
skirt, 90° to piston pin axis. Cylinder bores should be must be installed with the identification mark face
measured halfway down the cylinder bore and trans- up (toward top of piston) and chamfer facing down.
verse to the engine crankshaft center line. An identification mark on the ring is a drill point,
Pistons and cylinder bores should be measured at a stamped letter “O”, an oval depression or the
normal room temperature, 21°C (70°F). word TOP (Fig. 27) (Fig. 29).
Check the pistons for taper and elliptical shape (c) Using a ring installer, install the top com-
before they are fitted into the cylinder bore (Fig. 26). pression ring with the chamfer facing up (Fig. 28)
(Fig. 29). An identification mark on the ring is a
PISTON RINGS—FITTING drill point, a stamped letter “O”, an oval depression
(1) Measurement of end gaps: or the word TOP facing up.
(a) Measure piston ring gap 2 inches from bot- (d) Measure side clearance between piston ring
tom of cylinder bore. An inverted piston can be and ring land. Clearance should be 0.074-0.097 mm
used to push the rings down to ensure positioning (0.0029-0.0038 inch) for the compression rings. The
rings squarely in the cylinder bore before measur- steel rail oil ring should be free in groove, but
ing. should not exceed 0.246 mm (0.0097 inch) side
(b) Insert feeler gauge in the gap. The top com- clearance.
pression ring gap should be between 0.254-0.508 (e) Pistons with insufficient or excessive side
mm (0.010-0.020 inch). The second compression clearance should be replaced.

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 DN 5.9L ENGINE 9 - 157
SERVICE PROCEDURES (Continued)
PISTON MEASUREMENT CHART

PISTON A DIA = PISTON BORE

SIZE DIAMETER DIAMETER

MIN. MAX. MIN. MAX.

mm mm mm mm (in.)
(in.) (in.) (in.)

A — — — —

B 101.580 101.592 101.605 101.618

(3.9992) (3.9997) (4.0002) (4.0007) Fig. 27 Second Compression Ring Identification

(Typical)
C 101.592 101.605 101.618 101.630 1 – SECOND COMPRESSION RING (BLACK CAST IRON)
2 – CHAMFER
(3.9997) (4.0002) (4.0007) (4.0012) 3 – TWO DOTS

D 101.605 101.618 101.630 101.643

(4.0002) (4.0007) (4.0012) (4.0017)

E — — — —

DESCRIPTION SPECIFICATION

PISTON PIN BORE 25.007 - 25.015 mm

(.9845 -.9848 in.)

RING GROOVE
HEIGHT
OIL RAIL 4.033 - 4.058 mm
(.1588 -.1598 in.) Fig. 28 Top Compression Ring Identification
(Typical)
COMPRESSION 1.529 - 1.554 mm
1 – TOP COMPRESSION RING (GRAY IN COLOR)
RAIL
2 – CHAMFER
(.0602 -.0612 in.) 3 – ONE DOT

TOTAL FINISHED 470.8 6 2 grams

The bearing shells must be installed so that the
WEIGHT (16.607 6.0706 ounces)
tangs are in the machined grooves in the rods and
caps.
CONNECTING ROD BEARINGS—FITTING Limits of taper or out-of-round on any crankshaft
Fit all rods on a bank until completed. DO NOT journals should be held to 0.025 mm (0.001 inch).
alternate from one bank to another, because connect- Bearings are available in 0.025 mm (0.001 inch),
ing rods and pistons are not interchangeable from 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
one bank to another. mm (0.010 inch) and 0.305 mm (0.012 inch) under-
The bearing caps are not interchangeable and size. Install the bearings in pairs. DO NOT use a
should be marked at removal to ensure correct new bearing half with an old bearing half. DO
assembly. NOT file the rods or bearing caps.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing shell, CRANKSHAFT MAIN BEARINGS—FITTING
make certain that the V-groove in the shell is in line Bearing caps are not interchangeable and should
with the V-groove in the cap. This provides lubrica- be marked at removal to ensure correct assembly.
tion of the cylinder wall in the opposite bank. Upper and lower bearing halves are NOT inter-
changeable. Lower main bearing halves of No.2 and 4
are interchangeable.

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 9 - 158 5.9L ENGINE DN
SERVICE PROCEDURES (Continued)

Fig. 29 Compression Ring Chamfer Location

(Typical)
1 – CHAMFER
2 – TOP COMPRESSION RING
3 – SECOND COMPRESSION RING Fig. 31 Main Bearing Identification
4 – PISTON
5 – CHAMFER
REMOVAL AND INSTALLATION
ENGINE FRONT MOUNTS
REMOVAL—2WD
(1) Disconnect the negative cable from the battery.
(2) Raise hood and position fan to assure clearance
for radiator top tank and hose.

CAUTION: DO NOT lift the engine by the intake

manifold.

(3) Install engine lifting fixture.

(4) Raise vehicle on hoist.
(5) Remove the insulator through bolt (Fig. 32)
(Fig. 33).
(6) Raise engine with lifting fixture SLIGHTLY.
Remove insulator retaining bolts and remove the
insulator assembly.
Fig. 30 Proper Ring Installation (7) Remove insulator heat shield and transfer to
1 – OIL RING SPACER GAP new insulator.
2 – SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 – OIL RING RAIL GAP (BOTTOM) INSTALLATION—2WD
4 – TOP COMPRESSION RING GAP (1) With the engine raised SLIGHTLY, position
insulator assembly onto the engine block and install
bolts (Fig. 32) (Fig. 33). Tighten the bolts to 41 N·m
Upper and lower No.3 bearing halves are flanged
(30 ft. lbs.) torque.
to carry the crankshaft thrust loads. They are NOT
(2) Lower engine with lifting fixture while guiding
interchangeable with any other bearing halves in the
insulator assembly into the engine insulator bracket
engine (Fig. 31). Bearing shells are available in stan-
(Fig. 34).
dard and the following undersizes: 0.25 mm (0.001
(3) Install insulator to bracket thru-bolt. Tighten
inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
the thru-bolt nut to 68 N·m (50 ft. lbs.) torque.
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
(4) Remove lifting fixture.
Never install an undersize bearing that will reduce
(5) Connect the negative cable to the battery.
clearance below specifications.

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 DN 5.9L ENGINE 9 - 159
REMOVAL AND INSTALLATION (Continued)

Fig. 32 Engine Right Front Insulator Mount—2WD

Vehicles
1 – HEAT SHIELD
Fig. 34 Engine Mount Insulator at Frame
2 – INSULATOR 1 – NUT
2 – INSULATOR
3 – FRAME
4 – THROUGH BOLT

REMOVAL—4WD
On 4WD vehicles the engine front support brackets
attach directly to engine block and the axle housing.
The brackets provide a solid interconnection for these
units (Fig. 35) (Fig. 36). Engine must be supported
during any service procedures involving the front
support assemblies.
(1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist.
(3) Install engine lifting (support) fixture.
(4) Remove front axle. (Refer to Group 3, Differen-
tial and Driveline in this publication.)
(5) Left mount insulator only. Remove starter
wires and starter motor assembly.
(6) Remove insulator to frame through bolt (Fig.
37).
(7) Raise engine slightly.
(8) Remove upper insulator to support bracket
stud nut and insulator to support through bolt.
Fig. 33 Engine Left Front Insulator Mount—2WD (9) Remove engine mount insulator (Fig. 35) (Fig.
Vehicles 36).
1 – HEAT SHIELD
(10) If engine support bracket is to be removed/re-
2 – INSULATOR
placed, remove support bracket to transmission bell
housing bolt(s) and three (3) support bracket to
engine block bolts. Remove support bracket (Fig. 35)
(Fig. 36).

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 9 - 160 5.9L ENGINE DN
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 – INSULATOR 3 – FRONT AXLE
3 – FRONT AXLE

ENGINE REAR SUPPORT

INSTALLATION—4WD
(1) If engine support brackets were removed,
REMOVAL—2WD
install them and their fasteners (Fig. 35) (Fig. 36).
(1) Disconnect the negative cable from the battery.
Tighten support bracket to block bolts to 41 N·m (30
(2) Raise the vehicle on a hoist.
ft. lbs.). Tighten support bracket to transmission bell-
(3) Support the transmission with a jack.
housing bolt(s) to 88 N·m (65 ft. lbs.).
(4) Remove engine support bracket and insulator
(2) Install Engine mount insulator and tighten
thru-bolt (Fig. 38).
insulator to support bracket nut to 41 N·m (30 ft.
(5) Raise the transmission and engine slightly.
lbs.). Tighten insulator to support bracket through
(6) Remove stud nuts attaching insulator to cross-
bolt nut to 102 N·m (75 ft. lbs.).
member (Fig. 38). Remove insulator.
(3) Lower engine and install insulator to frame
through bolt and nut (Fig. 37). Tighten nut to 95 N·m
INSTALLATION—2WD
(70 ft. lbs.).
(1) If the engine support bracket was removed,
(4) Install starter motor and mounting bolts.
position the bracket to the transmission extension
Tighten bolts to 68 N·m (50 ft. lbs.).
(Fig. 38). Tighten the bolts to 68 N·m (50 ft. lbs.)
(5) Connect starter wires.
torque.
(6) Remove engine lifting (support) fixture.
(2) Install the insulator onto crossmember. Tighten
(7) Install front axle assembly (Refer to Group 3,
the stud nuts to 41 N·m (30 ft. lbs) torque.
Differential and Driveline).
(3) Lower the transmission and engine while align-
(8) Lower the vehicle.
ing the engine support bracket to the insulator.
(9) Connect the negative cable to the battery.
(4) Install thru-bolt in bracket and insulator.
Tighten thru-bolt nut to 68 N·m (50 ft. lbs.) torque.
(5) Remove transmission jack.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.

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 DN 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
1 – NUT 5 – TRANSMISSION EXTENSION
2 – ENGINE SUPPORT BRACKET
3 – INSULATOR
Install stud nuts and tighten to 28 N·m (250 in. lbs.)
4 – NUT
torque.
5 – THROUGH BOLT
6 – FRAME
(4) Remove the transmission jack.
7 – FRONT AXLE (5) Lower the vehicle.
(6) Connect the negative cable to the battery.

REMOVAL—4WD ENGINE ASSEMBLY

(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist. REMOVAL
(3) Support the transmission with a transmission (1) Scribe hood hinge outlines on hood. Remove the
jack. hood.
(4) Remove stud nuts holding the insulator to the (2) Remove the battery.
crossmember (Fig. 39). (3) Drain cooling system. Refer to COOLING SYS-
(5) Raise rear of transmission SLIGHTLY. TEM.
(6) Remove bolts holding the insulator to the insu- (4) Remove the air cleaner assembly and air inlet
lator bracket (Fig. 39). Remove the insulator. hose.
(5) Disconnect the radiator and heater hoses.
INSTALLATION—4WD (6) Set fan shroud aside.
(1) If the insulator bracket was removed, install (7) Remove the vacuum lines.
the bracket to the transmission (Fig. 39). Tighten the (8) Remove the distributor cap and wiring.
bolts to 28 N·m (250 in. lbs.) torque. (9) Disconnect the accelerator linkage.
(2) Install the bolts holding insulator to insulator (10) Remove throttle body.
bracket. Tighten the bolts to 28 N·m (250 in. lbs.) (11) Perform the Fuel System Pressure release
torque. procedure Refer to FUEL SYSTEM.
(3) Lower rear of transmission while aligning the (12) Disconnect the fuel lines.
insulator studs into the mounting support bracket. (13) Disconnect the starter wires.
(14) Disconnect the oil pressure wire.

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 9 - 162 5.9L ENGINE DN
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.
• RIGHT SIDE —Remove 2 bracket to axle (dis-
connect housing) bolts and a bracket to bell housing
bolt. Separate engine from insulator by removing
upper nut washer assembly and bolt from engine
support bracket.
(26) Lower the vehicle.
(27) Install engine assembly on engine repair
stand.

INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Install the engine front mounts.
(5) Refer to Group, 21 Transmissions for transmis-
sion installation
(6) Install the inspection plate.
(7) Remove transmission support.
(8) Install exhaust pipe to manifold.
Fig. 39 Rear Insulator—4WD Vehicles (9) Lower the vehicle.
1 – AUTOMATIC TRANSMISSION (10) Remove engine lifting fixture.
2 – INSULATOR BRACKET (11) Install the generator.
3 – INSULATOR (12) Install starter motor.
4 – CROSSMEMBER (13) Connect power steering hoses, if equipped.
(14) Connect air conditioning hoses.
(15) Discharge the air conditioning system, if (15) Evacuate and charge the air conditioning sys-
equipped. Refer to HEATING and AIR CONDITION- tem, if equipped.
ING. (16) Using a new gasket, install throttle body.
(16) Disconnect the air conditioning hoses. Tighten the throttle body bolts to 23 N·m (200 in.
(17) Disconnect the power steering hoses, if lbs.) torque.
equipped. (17) Connect the accelerator linkage.
(18) Remove starter motor. Refer to STARTING (18) Connect the starter wires.
SYSTEMS. (19) Connect the oil pressure wire.
(19) Remove the generator. (20) Install the distributor cap and wiring.
(20) Raise and support the vehicle on a hoist. (21) Connect the vacuum lines.
(21) Disconnect exhaust pipe at manifold. (22) Connect the fuel lines.
(22) Remove Transmission. Refer to TRANSMIS- (23) Install the radiator. Connect the radiator
SIONS. hoses and heater hoses.
(24) Install fan shroud in position.
CAUTION: DO NOT lift the engine by the intake (25) Fill cooling system.
manifold. (26) Install the air cleaner assembly and air inlet
hose.
(23) Install an engine lifting fixture. (27) Install the battery.
(24) 2WD VEHICLES —Remove engine front (28) Warm engine and adjust.
mount bolts. (29) Install hood and line up with the scribe
(25) 4WD VEHICLES —The engine and front marks.
driving axle (engine/axle/transmission) are connected (30) Road test vehicle.

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

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 9 - 164 5.9L ENGINE DN
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 – FLANGE GASKET
expected results of the automated assembly system 2 – ALIGNMENT TABS
(Fig. 44). 3 – CYLINDER HEAD GASKET
• 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. lbs.) torque.
• Step 3—Check that all bolts are tightened to 8
N·m (72 in. lbs.) torque.
• Step 4—Tighten all bolts, in sequence, to 16 N·m
(12 ft. lbs.) torque.
• Step 5—Check that all bolts are tightened to 16
N·m (12 ft. lbs.) torque.
(10) Install closed crankcase ventilation and evap-
oration control systems.
(11) Install the coil wires.
(12) Connect the coolant temperature sending unit
wire.
(13) Connect the heater hoses and bypass hose. Fig. 44 Intake Manifold Bolt Tightening Sequence—
(14) Install distributor cap and wires. 5.9L Engine
(15) Connect the accelerator linkage and, if so (18) Install the generator and accessory drive belt.
equipped, the speed control and transmission kick- Tighten generator mounting bolt to 41 N·m (30 ft.
down cables. lbs.) torque.
(16) Install the fuel supply line to the fuel rail. (19) Install the air cleaner assembly and air inlet
(17) Install the accessory drive bracket and A/C hose.
compressor. (20) Fill cooling system.
(21) Connect the battery negative cable.

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 DN 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. 45).
(6) Remove two nuts, heat shield and washers
from the left side exhaust manifold, if necessary (Fig.
46).
(7) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(8) Remove manifold from the cylinder head.
Fig. 46 Exhaust Manifold Heat Shield—Left Side
1 – WASHER
2 – NUT AND WASHER
3 – EXHAUST MANIFOLD HEAT SHIELD

Fig. 45 Exhaust Manifold Heat Shield—Right Side

1 – WASHER
2 – NUT AND WASHER
3 – EXHAUST MANIFOLD HEAT SHIELD
Fig. 47 Exhaust Manifold Installation—5.9L Engine
1 – EXHAUST MANIFOLD (LEFT)
INSTALLATION 2 – BOLTS & WASHERS
3 – NUTS & WASHERS
CAUTION: If the studs came out with the nuts when 4 – EXHAUST MANIFOLD (RIGHT)
removing the exhaust manifold, install new studs. 5 – BOLTS & WASHERS

(1) Position the exhaust manifolds on the two (6) Assemble the exhaust pipe to the exhaust man-
studs located on the cylinder head. Install conical ifold and secure with bolts, nuts and washers.
washers and nuts on these studs (Fig. 47). Tighten these nuts to 27 N·m (20 ft. lbs.) torque.
(2) Install new bolt and washer assemblies in the (7) Lower the vehicle.
remaining holes (Fig. 47). Start at the center arm (8) Connect the battery negative cable.
and work outward. Tighten the bolts and nuts to 24
N·m (18 ft. lbs.) torque.
CYLINDER HEAD COVER
(3) Position three washers, heat shield and nuts on
A steel backed silicon gasket is used with the cyl-
the right side exhaust manifold. Tighten nuts to 24
inder head cover (Fig. 48). This gasket can be used
N·m (18 ft. lbs.).
again.
(4) Position two washers, heat shield and nuts on
the left side exhaust manifold. Tighten nuts to 24
REMOVAL
N·m (18 ft. lbs.).
(1) Disconnect the negative cable from the battery.
(5) Raise the vehicle.

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 9 - 166 5.9L ENGINE DN
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.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 N·m (21 ft. lbs.) torque.

Fig. 48 Cylinder Head Cover Gasket CAUTION: DO NOT rotate or crank the engine dur-
1 – CYLINDER HEAD COVER GASKET ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(2) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover. (4) Install cylinder head cover.
(3) Remove the air inlet hose.
(4) Remove cylinder head cover and gasket. The VALVE SPRING AND STEM SEAL
gasket may be used again.
REPLACEMENT-IN VEHICLE
INSTALLATION (1) Remove the air cleaner.
(1) The cylinder head cover gasket can be used (2) Remove cylinder head covers and spark plugs.
again. Install the gasket onto the head rail. (3) Remove coil wire from distributor and secure to
(2) Position the cylinder head cover onto the gas- good ground to prevent engine from starting.
ket. Tighten the bolts to 11 N·m (95 in. lbs.) torque. (4) Using suitable socket and flex handle at crank-
(3) Install closed crankcase ventilation system and shaft retaining bolt, turn engine so the No.1 piston is
evaporation control system. at TDC on the compression stroke.
(4) Install the air inlet hose. (5) Remove rocker arms.
(5) Connect the negative cable to the battery. (6) With air hose attached to an adapter installed
in No.1 spark plug hole, apply 620-689 kPa (90-100
ROCKER ARMS AND PUSH RODS psi) air pressure.
(7) Using Valve Spring Compressor Tool
REMOVAL MD-998772A with adaptor 6716A, compress valve
(1) Remove cylinder head cover and gasket. Refer spring and remove retainer valve locks and valve
to Cylinder Head Cover in this section for correct spring.
procedure. (8) Install seals on the exhaust valve stem and
(2) Remove the rocker arm bolts and pivots (Fig. position down against valve guides.
49). Place them on a bench in the same order as (9) The intake valve stem seals should be pushed
removed. firmly and squarely over the valve guide using the
(3) Remove the push rods and place them on a valve stem as a guide. DO NOT force seal against top
bench in the same order as removed. of guide. When installing the valve retainer locks,
compress the spring only enough to install the locks.
(10) Follow the same procedure on the remaining 7
cylinders using the firing sequence 1-8-4-3-6-5-7-2.
Make sure piston in cylinder is at TDC on the valve
spring that is being removed.
(11) Remove adapter from the No.1 spark plug
hole and install spark plugs.
(12) Install rocker arms.
(13) Install covers and coil wire to distributor.
(14) Install air cleaner.
(15) Road test vehicle.
Fig. 49 Rocker Arms
1 – ROCKER ARMS
2 – CYLINDER HEAD

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 DN 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 the intake manifold-to-generator
bracket support rod. Remove the generator.
(4) Remove closed crankcase ventilation system.
(5) Disconnect the evaporation control system.
(6) Remove the air cleaner assembly and air inlet
hose.
(7) Perform fuel system pressure release proce-
dure. Refer to FUEL SYSTEM.
(8) Disconnect the fuel supply line.
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
Fig. 50 Cylinder Head Bolt Tightening Sequence
down cables. (6) Install exhaust manifolds. Tighten the bolts
(10) Remove distributor cap and wires. and nuts to 34 N·m (25 ft. lbs.) torque.
(11) Disconnect the coil wires. (7) Adjust spark plugs to specifications. Refer to
(12) Disconnect heat indicator sending unit wire. IGNITION SYSTEM. Install the plugs and tighten to
(13) Disconnect heater hoses and bypass hose. 41 N·m (30 ft. lbs.) torque.
(14) Remove cylinder head covers and gaskets. (8) Install coil wires.
(15) Remove intake manifold and throttle body as (9) Connect heat indicator sending unit wire.
an assembly. Discard the flange side gaskets and the (10) Connect the heater hoses and bypass hose.
front and rear cross-over gaskets. (11) Install distributor cap and wires.
(16) Remove exhaust manifolds. (12) Connect the accelerator linkage and if so
(17) Remove rocker arm assemblies and push rods. equipped, the speed control and transmission kick-
Identify to ensure installation in original locations. down cables.
(18) Remove the head bolts from each cylinder (13) Install the fuel supply line.
head and remove cylinder heads. Discard the cylin- (14) Install the generator and drive belt. Tighten
der head gasket. generator mounting bolt to 41 N·m (30 ft. lbs.)
(19) Remove spark plugs. torque.
(15) Install the intake manifold-to-generator
INSTALLATION bracket support rod. Tighten the bolts.
(1) Position the new cylinder head gaskets onto (16) Place the cylinder head cover gaskets in posi-
the cylinder block. tion and install cylinder head covers. Tighten the
(2) Position the cylinder heads onto head gaskets bolts to 11 N·m (95 in. lbs.) torque.
and cylinder block. (17) Install closed crankcase ventilation system.
(3) Starting at top center, tighten all cylinder head (18) Connect the evaporation control system.
bolts, in sequence, to 68 N·m (50 ft. lbs.) torque (Fig. (19) Install the air cleaner assembly and air inlet
50). Repeat procedure, tighten all cylinder head bolts hose.
to 143 N·m (105 ft. lbs.) torque. Repeat procedure to (20) Install the heat shields. Tighten the bolts to
confirm that all bolts are at 143 N·m (105 ft. lbs.) 41 N·m (30 ft. lbs.) torque.
torque. (21) Fill cooling system.
(22) Connect the battery negative cable.
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at VALVES AND VALVE SPRINGS
TDC. Contact between the valves and piston could
occur. REMOVAL
(1) Remove the cylinder head.
(4) Install push rods and rocker arm assemblies in (2) Compress valve springs using Valve Spring
their original position. Tighten the bolts to 28 N·m Compressor Tool MD- 998772A.
(21 ft. lbs.) torque. (3) Remove valve retaining locks, valve spring
(5) Install the intake manifold and throttle body retainers, valve stem seals and valve springs.
assembly.

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 9 - 168 5.9L ENGINE DN
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.
original location. (10) Start and operate engine. Warm up to normal
operating temperature.
INSTALLATION
(1) Coat valve stems with lubrication oil and insert CAUTION: To prevent damage to valve mechanism,
them in cylinder head. engine must not be run above fast idle until all
(2) If valves or seats are reground, check valve hydraulic tappets have filled with oil and have
stem height. If valve is too long, replace cylinder become quiet.
head.
(3) Install new seals on all valve guides. Install
valve springs and valve retainers. VIBRATION DAMPER
(4) Compress valve springs with Valve Spring
Compressor Tool MD-998772A, install locks and REMOVAL
release tool. If valves and/or seats are ground, mea- (1) Disconnect the battery negative cable.
sure the installed height of springs. Make sure the (2) Remove the cooling system fan.
measurement is taken from bottom of spring seat in (3) Remove the cooling fan shroud.
cylinder head to the bottom surface of spring (4) Remove the accessory drive belt. Refer to
retainer. If spacers are installed, measure from the COOLING SYSTEM.
top of spacer. If height is greater than 42.86 mm (5) Remove vibration damper bolt and washer from
(1-11/16 inches), install a 1.587 mm (1/16 inch) end of crankshaft.
spacer in head counterbore. This should bring spring (6) Position Special Tool 8513 Insert into the
height back to normal 41.27 to 42.86 mm (1-5/8 to crankshaft nose.
1-11/16 inch). (7) Install Special Tool 1026 Three Jaw Puller onto
the vibration damper (Fig. 51).
HYDRAULIC TAPPETS
REMOVAL
(1) Remove the air cleaner assembly and air inlet
hose.
(2) Remove cylinder head cover, rocker assembly
and push rods. Identify push rods to ensure installa-
tion in original location.
(3) Remove intake manifold, yoke retainer and
aligning yokes.
(4) Slide Hydraulic Tappet Remover/Installer Tool
C-4129-A through opening in cylinder head and seat
tool firmly in the head of tappet.
(5) Pull tappet out of bore with a twisting motion. Fig. 51 Vibration Damper Removal
If all tappets are to be removed, identify tappets to 1 – SPECIAL TOOL 8513 INSERT
ensure installation in original location. 2 – SPECIAL TOOL 1026

INSTALLATION (8) Pull vibration damper off of the crankshaft.

(1) If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to INSTALLATION
next oversize. Replace with oversize tappet.
(2) Lubricate tappets. CAUTION: Thoroughly remove any contaminants
(3) Install tappets and push rods in their original from the crankshaft nose and the vibration damper
positions. Ensure that the oil feed hole in the side of bore. Failure to do so can cause sever damage to
the tappet body faces up (away from the crankshaft). the crankshaft.
(4) Install aligning yokes with ARROW toward
camshaft. (1) Position the vibration damper onto the crank-
(5) Install yoke retainer. Tighten the bolts to 23 shaft.
N·m (200 in. lbs.) torque. Install intake manifold.
(6) Install push rods in original positions.

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 DN 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.
Use a small amount of Mopar Silicone Rubber Adhe-
sive Sealant, or equivalent, at the joint between tim-
Fig. 52 Vibration Damper Installation
ing chain cover gasket and the oil pan gasket. Finger
1 – SPECIAL TOOL C-3688
tighten the timing chain cover bolts at this time.
(4) Place the smaller diameter of the oil seal over
(3) Install the crankshaft bolt and washer. Tighten Front Oil Seal Installation Tool 6635 (Fig. 54). Seat
the bolt to 244 N·m (180 ft. lbs.) torque. the oil seal in the groove of the tool.
(4) Install the accessory drive belt.
(5) Position the fan shroud and install the bolts.
Tighten the retainer bolts to 11 N·m (95 in. lbs.)
torque.
(6) Install the cooling fan.
(7) Connect the battery negative cable.

TIMING CHAIN COVER

(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (refer to Group 7, Cooling
System).
(3) Remove the serpentine belt (refer to Group 7,
Cooling System).
(4) Remove water pump (refer to Group 7, Cooling
System).
(5) Remove power steering pump (refer to Group
19, Steering). Fig. 54 Placing Oil Seal on Installation Tool 6635
(6) Remove vibration damper. 1 – CRANKSHAFT FRONT OIL SEAL
(7) Remove fuel lines (refer to Group 14, Fuel Sys- 2 – INSTALL THIS END INTO SPECIAL TOOL 6635
tem).
(8) Loosen oil pan bolts and remove the front bolt
(5) Position the seal and tool onto the crankshaft
at each side.
(Fig. 55).
(9) Remove the cover bolts.
(6) Tighten the 4 lower chain case cover bolts to
(10) Remove chain case cover and gasket using
13N·m (10 ft.lbs.) to prevent the cover from tipping
extreme caution to avoid damaging oil pan gasket.
during seal installation.
(11) Place a suitable tool behind the lips of the oil
(7) Using the vibration damper bolt, tighten the
seal to pry the oil seal outward. Be careful not to
bolt to draw the seal into position on the crankshaft
damage the crankshaft seal surface of cover (Fig. 53).
(Fig. 56).
(8) Loosen the 4 bolts tightened in step 4 to allow
INSTALLATION
realignment of front cover assembly.
(1) Be sure mating surfaces of chain case cover
(9) Tighten chain case cover bolts to 41 N·m (30 ft.
and cylinder block are clean and free from burrs.
lbs.) torque. Tighten oil pan bolts to 24 N·m (215 in.
(2) The water pump mounting surface must be
lbs.) torque.
cleaned.

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 9 - 170 5.9L ENGINE DN
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).
(14) Install the serpentine belt (refer to Group 7,
Cooling System).
(15) Install the cooling system fan. Tighten the
bolts to 23 N·m (17 ft. lbs.) torque.
(16) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N·m (95 in. lbs.) torque.
(17) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure).
(18) Connect the negative cable to the battery.

TIMING CHAIN
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove Timing Chain Cover. Refer to Timing
Chain Cover in this section for correct procedure.
(3) Re-install the vibration damper bolt finger
Fig. 55 Position Tool and Seal onto Crankshaft
tight. Using a suitable socket and breaker bar, rotate
1 – SPECIAL TOOL 6635
2 – OIL SEAL
the crankshaft to align timing marks as shown in
3 – TIMING CHAIN COVER (Fig. 57).
(4) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.

INSTALLATION
(1) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(2) Place timing chain around both sprockets.
(3) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(4) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(5) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 57).
(6) Install the camshaft bolt. Tighten the bolt to 68
N·m (50 ft. lbs.) torque.
(7) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
Fig. 56 Installing Oil Seal used thrust plate. If not within these limits install a
1 – SPECIAL TOOL 6635 new thrust plate.
2 – TIMING CHAIN COVER (8) Install the timing chain cover.

CAMSHAFT
(10) Remove the vibration damper bolt and seal
installation tool. NOTE: The camshaft has an integral oil pump and
(11) Install vibration damper. distributor drive gear (Fig. 58).

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 DN 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
Fig. 58 Camshaft and Sprocket Assembly 3 – THRUST PLATE REAR SIDE
1 – THRUST PLATE
2 – OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL (2) Install Camshaft Gear Installer Tool C-3509
WITH CAMSHAFT
3 – CAMSHAFT SPROCKET
with tongue back of distributor drive gear (Fig. 60).

REMOVAL
(1) Remove the radiator. Refer to Group 7, Cooling
for the correct procedures.
(2) Remove the A/C Condenser (if equipped).
(3) Remove the engine cover.
(4) Remove intake manifold. Refer to Intake Man-
ifold in this section for the correct procedure.
(5) Remove cylinder head covers.
(6) Remove timing case cover and timing chain.
(7) Remove rocker arms.
(8) Remove push rods and tappets. Identify each Fig. 60 Camshaft Holding Tool C-3509 (Installed
part so it can be installed in its original location. Position)
(9) Remove distributor and lift out the oil pump 1 – SPECIAL TOOL C-3509
and distributor drive shaft. 2 – DRIVE GEAR
(10) Remove camshaft thrust plate, note location of 3 – DISTRIBUTOR LOCK BOLT
oil tab (Fig. 59).
(11) Install a long bolt into front of camshaft to aid (3) Hold tool in position with a distributor lock-
in removal of the camshaft. Remove camshaft, being plate bolt. This tool will restrict camshaft from being
careful not to damage cam bearings with the cam pushed in too far and prevent knocking out the welch
lobes. plug in rear of cylinder block. Tool should remain
installed until the camshaft and crankshaft
INSTALLATION sprockets and timing chain have been installed.
(1) Lubricate camshaft lobes and camshaft bearing (4) Install camshaft thrust plate and chain oil tab.
journals and insert the camshaft to within 51 mm (2 Make sure tang enters lower right hole in
inches) of its final position in cylinder block. thrust plate. Tighten bolts to 24 N·m (210 in. lbs.)

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 9 - 172 5.9L ENGINE DN
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. removed from the vehicle.
(6) Place timing chain around both sprockets.
(7) Turn crankshaft and camshaft to line up with (1) With engine completely disassembled, drive out
keyway location in crankshaft sprocket and in cam- rear cam bearing core plug.
shaft sprocket. (2) Install proper size adapters and horseshoe
(8) Lift sprockets and chain (keep sprockets tight washers (part of Camshaft Bearing Remover/Installer
against the chain in position as described). Tool C-3132-A) at back of each bearing shell. Drive
(9) Slide both sprockets evenly over their respec- out bearing shells (Fig. 62).
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 61).

Fig. 62 Camshaft Bearings Removal/Installation with

Fig. 61 Alignment of Timing Marks Tool C-3132-A
1 – TIMING MARKS 1 – SPECIAL TOOL C-3132–A
2 – MAIN BEARING OIL HOLE

(10) Install the camshaft bolt/cup washer. Tighten

bolt to 68 N·m (50 ft. lbs.) torque. INSTALLATION
(11) Measure camshaft end play. Refer to Specifica- (1) Install new camshaft bearings with Camshaft
tions for proper clearance. If not within limits install Bearing Remover/Installer Tool C-3132-A by sliding
a new thrust plate. the new camshaft bearing shell over proper adapter.
(12) Each tappet reused must be installed in the (2) Position rear bearing in the tool. Install horse-
same position from which it was removed. When shoe lock and by reversing removal procedure, care-
camshaft is replaced, all of the tappets must be fully drive bearing shell into place.
replaced. (3) Install remaining bearings in the same man-
(13) Install distributor and distributor drive shaft. ner. Bearings must be carefully aligned to bring oil
(14) Install push rods and tappets. holes into full register with oil passages from the
(15) Install rocker arms. main bearing. If the camshaft bearing shell oil holes
(16) Install timing case cover. are not in exact alignment, remove and install them
(17) Install cylinder head covers. correctly. Install a new core hole plug at the rear of
(18) Install intake manifold. camshaft. Be sure this plug does not leak.
(19) Install the engine cover.
(20) Install the A/C Condenser (if equipped) DISTRIBUTOR DRIVE SHAFT BUSHING
(21) Install the radiator. Refer to Group 7, Cooling
for the correct procedures. REMOVAL
(22) Refill cooling system. Refer to Group 7, Cool- (1) Remove distributor, refer to Group 8D, Ignition
ing for the correct procedures. Systems for the proper procedure.
(23) Start engine check for leaks. (2) Remove the intake manifold. Refer to Intake
Manifold in this section for correct procedure.
(3) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and thread down until a
tight fit is obtained (Fig. 63).

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 DN 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 – SPECIAL TOOL C-3052
2 – BUSHING (1) Rotate crankshaft until No.1 cylinder is at top
dead center on the firing stroke.
(2) When in this position, the timing mark of
INSTALLATION
vibration damper should be under “0” on the timing
(1) Slide new bushing over burnishing end of Dis-
indicator.
tributor Drive Shaft Bushing Driver/Burnisher Tool
(3) Install the shaft so that after the gear spirals
C-3053. Insert the tool and bushing into the bore.
into place, it will index with the oil pump shaft. The
(2) Drive bushing and tool into position, using a
slot on top of oil pump shaft should be aligned
hammer (Fig. 64).
towards the left front intake manifold attaching bolt
hole (Fig. 66).

Fig. 64 Distributor Driveshaft Bushing Installation

1 – SPECIAL TOOL C-3053
2 – BUSHING
Fig. 66 Position of Oil Pump Shaft Slot
1 – DISTRIBUTOR DRIVE

(3) As the burnisher is pulled through the bushing,

the bushing is expanded tight in the block and bur- (4) Install distributor, refer to Group 8D, Ignition
nished to correct size (Fig. 65). DO NOT ream this Systems for the proper procedure.
bushing. After the distributor has been installed, its rota-
tional position must be set using the SET SYNC
CAUTION: This procedure MUST be followed when mode of the DRB scan tool. Refer to Checking Dis-
installing a new bushing or seizure to shaft may tributor Position following the Distributor Installa-
occur. tion section in Group 8D, Ignition system.
Do not attempt to adjust ignition timing by
(4) Install the intake manifold. rotating the distributor. It has no effect on igni-
tion timing. Adjusting distributor position will
DISTRIBUTOR INSTALLATION effect fuel synchronization only.

NOTE: Before installing the distributor, the oil

pump drive shaft must be aligned to number one
cylinder.

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 9 - 174 5.9L ENGINE DN
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.
(1) Remove the oil pan. (6) Disconnect throttle valve cable from throttle
(2) Remove the oil pump from the rear main bear- body and mounting bracket (Fig. 67A).
ing cap.
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 67).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.

Fig. 67A Throttle Valve Cable Removal/Installation

1 – TRANSMISSION THROTTLE VALVE CABLE BRACKET
2 – AIR INLET DUCT
Fig. 67 Upper Main Bearing Removal and 3 – TRANSMISSION THROTTLE VALVE CABLE
Installation with Tool C-3059
1 – SPECIAL TOOL C-3059 (7) Raise vehicle.
2 – BEARING (8) Drain engine oil.
3 – SPECIAL TOOL C-3059 (9) Remove exhaust pipe from exhaust manifolds.
4 – BEARING (10) Remove engine mount insulator through bolts.
(11) Raise engine by way of oil pan using a block of
wood between the jack and oil pan.
INSTALLATION (12) When engine is high enough, place mount
Only one main bearing should be selectively fitted through bolts in the engine mount attaching points on
while all other main bearing caps are properly tight- the frame brackets.
ened. All bearing capbolts removed during service (13) Lower engine so bottom of engine mounts rest
procedures are to be cleaned and oiled before instal- on the replacement bolts placed in the engine mount
lation. frame brackets.
When installing a new upper bearing shell, slightly (14) Remove transmission to engine braces.
chamfer the sharp edges from the plain side. (15) Remove starter. Refer to STARTING SYS-
(1) Start bearing in place, and insert Crankshaft TEMS.
Main Bearing Remover/Installer Tool C-3059 into oil (16) Remove transmission torque converter inspec-
hole of crankshaft (Fig. 67). tion cover.
(2) Slowly rotate crankshaft counterclockwise slid- (17) Disconnect rear support cushion from cross-
ing the bearing into position. Remove Tool C-3059. member.
(3) Install the bearing caps. Clean and oil the bolts. (18) Raise rear of transmission away from cross-
Tighten the capbolts to 115 N·m (85 ft. lbs.) torque. member.
(4) Install the oil pump. (19) Remove oil pan and one-piece gasket.
(5) Install the oil pan.
(6) Start engine check for leaks. 4WD
(1) Disconnect the negative cable from the battery.
OIL PAN (2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
REMOVAL (5) Remove front driving axle. Refer to DIFFEREN-
TIAL and DRIVELINE.
2WD (6) Remove both engine mount support brackets.
(1) Disconnect the negative cable from the battery. (7) Remove transmission torque converter inspec-
(2) Remove air cleaner assembly. tion cover.
(3) Remove engine oil dipstick. (8) Remove oil pan and one-piece gasket.

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 DN 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
2WD bolts and tighten to 95 N·m (70 ft. lbs.).
(1) Fabricate 4 alignment dowels from 5/16 x 1 1/2 (13) Install starter.
inch bolts. Cut the head off the bolts and cut a slot (14) Install transmission torque converter inspec-
into the top of the dowel. This will allow easier instal- tion cover.
lation and removal with a screwdriver (Fig. 68). (15) Install engine to transmission braces.
(16) Install exhaust pipe.
(17) Lower vehicle.
(18) Position throttle valve cable into bracket, then
attach to throttle body (Fig. 67A).
(19) Connect the distributor cap.
(20) Install dipstick.
(21) Install fan shroud.
(22) Install air cleaner assembly.
(23) Connect the negative cable to the battery.
(24) Fill crankcase with oil to proper level.
Fig. 68 Fabrication of Alignment Dowels 4WD
1 – 1 1/2” x 5/16” BOLT (1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
2 – DOWEL inch bolts. Cut the head off the bolts and cut a slot
3 – SLOT into the top of the dowel. This will allow easier instal-
lation and removal with a screwdriver (Fig. 68).
(2) Install the dowels in the cylinder block (Fig. 69).
(2) Install the dowels in the cylinder block (Fig. 69). (3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
N·m (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil pan
bolts. Tighten these bolts to 24 N·m (215 in. lbs.) torque.
(8) Install the drain plug. Tighten drain plug to 34
N·m (25 ft. lbs.) torque.
(9) Install transmission inspection cover.
(10) Install engine mount support brackets and
insulators.
(11) Install front drive axle. Refer to DIFFEREN-
TIAL and DRIVELINE.
Fig. 69 Position of Dowels in Cylinder Block (12) Lower vehicle
1 – DOWEL (13) Connect the distributor cap.
2 – DOWEL (14) Install dipstick.
3 – DOWEL
(15) Connect the negative cable to the battery.
(16) Fill crankcase with oil to proper level.
4 – DOWEL

(3) Apply small amount of Mopar Silicone Rubber

PISTON AND CONNECTING ROD ASSEMBLY
Adhesive Sealant, or equivalent in the corner of the REMOVAL
cap and the cylinder block. (1) Remove the engine from the vehicle.
(4) Slide the one-piece gasket over the dowels and (2) Remove the cylinder head.
onto the block. (3) Remove the oil pan.
(5) Position the oil pan over the dowels and onto (4) Remove top ridge of cylinder bores with a reli-
the gasket. able ridge reamer before removing pistons from cylin-
(6) Install the oil pan bolts. Tighten the bolts to 24 der block. Be sure to keep tops of pistons covered
N·m (215 in. lbs.) torque. during this operation.
(7) Remove the dowels. Install the remaining oil (5) Be sure the connecting rod and connecting rod
pan bolts. Tighten these bolts to 24 N·m (215 in. lbs.) cap are identified with the cylinder number. Remove
torque. connecting rod cap. Install connecting rod bolt guide
(8) Install the drain plug. Tighten drain plug to 34 set on connecting rod bolts.
N·m (25 ft. lbs.) torque. (6) Pistons and connecting rods must be removed
(9) Lower transmission onto crossmember. from top of cylinder block. When removing piston and
(10) Install rear support cushion mounting bolts. connecting rod assemblies, rotate crankshaft to center
Tighten bolts 28 N·m (250 in. lbs.). the connecting rod in the cylinder bore and at BDC.
(11) Raise engine by way of oil pan with a wood Be careful not to nick crankshaft journals.
block placed between jack and oil pan.
(7) After removal, install bearing cap on the mating rod.

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 9 - 176 5.9L ENGINE DN
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. 71).
sure the oil ring expander ends are butted and the FOR EXAMPLE: R2 stamped on the No.3 crank-
rail gaps located properly (Fig. 70). shaft counterweight indicates that the No.2 rod jour-
nal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in)
undersize. R3 M2 indicates that the No.3 rod journal
and the No.2 main journal are 0.025 mm (0.001 in)
undersize.

Fig. 70 Proper Ring Installation

1 – OIL RING SPACER GAP
2 – SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP) Fig. 71 Location of Crankshaft Identification
3 – OIL RING RAIL GAP (BOTTOM) 1 – 1/4” LETTERS
4 – TOP COMPRESSION RING GAP 2 – (ROD)
3 – (MAIN)

(3) Immerse the piston head and rings in clean

engine oil. Slide Piston Ring Compressor Tool C-385 CRANKSHAFT IDENTIFICATION MARK
over the piston and tighten with the special wrench LOCATION CHART
(part of Tool C-385). Be sure position of rings
does not change during this operation. UNDERSIZE JOURNAL IDENTIFICATION
(4) Install connecting rod bolt protectors on rod STAMP
bolts, the long protector should be installed on the
0.025 mm (0.001 in.) R1-R2-R3 or R4
numbered side of the connecting rod.
(ROD)
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure 0.025 mm (0.001 in.) M1-M2-M3-M4 or M5
connecting rod and cylinder bore number are the (MAIN)
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal. When a crankshaft is replaced, all main and con-
(6) Tap the piston down in cylinder bore, using a necting rod bearings should be replaced with new
hammer handle. At the same time, guide connecting bearings. Therefore, selective fitting of the bearings
rod into position on crankshaft journal. is not required when a crankshaft and bearings are
(7) The notch or groove on top of piston must be replaced.
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward REMOVAL
crankshaft journal fillet. (1) Remove the oil pan.
(8) Install rod caps. Be sure connecting rod, con- (2) Remove the oil pump from the rear main bear-
necting rod cap and cylinder bore number are the ing cap.
same. Install nuts on cleaned and oiled rod bolts and (3) Remove the vibration damper.
tighten nuts to 61 N·m (45 ft. lbs.) torque. (4) Remove the timing chain cover.
(9) Install the oil pan. (5) Identify bearing caps before removal. Remove
(10) Install the cylinder head. bearing caps and bearings one at a time.
(11) Install the engine into the vehicle. (6) Lift the crankshaft out of the block.

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 DN 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. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 inch).
Journal grinding should not exceed 0.305 mm
(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO
NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and
clean out all oil passages. Fig. 72 Sealant Application to Bearing Cap
1 – .25 DROP OF LOCTITE 515 ON BOTH SIDES OF REAR
MAIN CAP
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction as the engine rotates. Withdraw nozzle and wipe excess sealant off the oil
pan seal groove.
(10) Install new front crankshaft oil seal.
CLEANING (11) Immediately install the oil pan.
Clean Loctite 518 residue and sealant from the cyl-
inder block and rear cap mating surface. Do this
before applying the Loctite drop and the installation
of rear cap.

INSTALLATION
(1) Lightly oil the new upper seal lips with engine
oil.
(2) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine
oil.
(5) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine. Fig. 73 Apply Sealant to Bearing Cap to Block Joint
(6) Apply 5 mm (0.20 in) drop of Loctite 518, or 1 – MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE
equivalent, on each side of the rear main bearing cap TIP
(Fig. 72). DO NOT over apply sealant or allow the 2 – SEALANT APPLIED
sealant to contact the rubber seal. Assemble bearing 3 – CYLINDER BLOCK
cap to cylinder block immediately after sealant appli- 4 – REAR MAIN BEARING CAP
cation.
(7) To align the bearing cap, use cap slot, align-
OIL PUMP
ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
REMOVAL
more than 2 times for proper engagement.
(1) Remove the oil pan.
(8) Clean and oil all cap bolts. Install all main
(2) Remove the oil pump from rear main bearing
bearing caps. Install all cap bolts and alternately
cap.
tighten to 115 N·m (85 ft. lbs.) torque.
(9) Install oil pump.
INSTALLATION
Apply Mopart Silicone Rubber Adhesive Sealant,
(1) Install oil pump. During installation slowly
or equivalent, at bearing cap to block joint to provide
rotate pump body to ensure driveshaft-to-pump rotor
cap to block and oil pan sealing (Fig. 73). Apply
shaft engagement.
enough sealant until a small amount is squeezed out.

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 9 - 178 5.9L ENGINE DN
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-
aligned.
(1) Disconnect the negative cable from the battery.
(2) Remove vibration damper.
(3) If front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa-
tion/alignment tool 6635, should fit with minimum
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.
(5) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 74). Seat
Fig. 75 Position Tool and Seal onto Crankshaft
the oil seal in the groove of the tool.
1 – SPECIAL TOOL 6635
2 – OIL SEAL
3 – TIMING CHAIN COVER

Fig. 74 Placing Oil Seal on Installation Tool 6635

1 – CRANKSHAFT FRONT OIL SEAL
2 – INSTALL THIS END INTO SPECIAL TOOL 6635

(6) Position the seal and tool onto the crankshaft

(Fig. 75).
(7) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 76).
(8) Remove the vibration damper bolt and seal Fig. 76 Installing Oil Seal
installation tool. 1 – SPECIAL TOOL 6635
(9) Inspect the seal flange on the vibration 2 – TIMING CHAIN COVER
damper.
(10) Install the vibration damper.
(11) Connect the negative cable to the battery.

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 DN 5.9L ENGINE 9 - 179
REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT OIL SEALS—REAR (8) To align the bearing cap, use cap slot, align-
The service seal is a 2 piece, viton seal. The upper ment dowel and cap bolts. DO NOT remove excess
seal half can be installed with crankshaft removed material after assembly. DO NOT strike rear cap
from engine or with crankshaft installed. When a more than 2 times for proper engagement.
new upper seal is installed, install a new lower seal. (9) Clean and oil all cap bolts. Install all main
The lower seal half can only be installed with the bearing caps. Install all cap bolts and alternately
rear main bearing cap removed. tighten to 115 N·m (85 ft. lbs.) torque.
(10) Install oil pump.
UPPER SEAL —CRANKSHAFT REMOVED (11) Apply Mopart Silicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
REMOVAL provide cap to block and oil pan sealing (Fig. 78).
(1) Remove the crankshaft. Discard the old upper Apply enough sealant until a small amount is
seal. squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
INSTALLATION (12) Install new front crankshaft oil seal.
(1) Clean the cylinder block rear cap mating sur- (13) Immediately install the oil pan.
face. Make sure the seal groove is free of debris.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of Mopart Gasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 77). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after Fig. 78 Apply Sealant to Bearing Cap to Block Joint
sealant application. 1 – MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE
TIP
2 – SEALANT APPLIED
3 – CYLINDER BLOCK
4 – REAR MAIN BEARING CAP

UPPER SEAL —CRANKSHAFT INSTALLED

REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal.
(4) Carefully remove and discard the old upper oil
seal.

INSTALLATION
Fig. 77 Sealant Application to Bearing Cap (1) Clean the cylinder block mating surfaces before
1 – MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS oil seal installation. Check for burr at the oil hole on
2 – LOCTITE 518 (OR EQUIVALENT)
the cylinder block mating surface to rear cap.
3 – CAP ALIGNMENT SLOT
(2) Lightly oil the new upper seal lips with engine
4 – REAR MAIN BEARING CAP
oil. To allow ease of installation of the seal, loosen at

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 9 - 180 5.9L ENGINE DN
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.
block being careful not to shave or cut the outer sur- (6) To align the bearing cap, use cap slot, align-
face of the seal. To assure proper installation, use the ment dowel and cap bolts. DO NOT remove excess
installation tool provided with the kit. Install the material after assembly. DO NOT strike rear cap
new seal with the white paint facing towards the more than 2 times for proper engagement.
rear of the engine. (7) Install the rear main bearing cap with cleaned
(4) Install the new lower rear bearing oil seal into and oiled cap bolts. Alternately tighten the cap bolts
the bearing cap with the white paint facing towards to 115 N·m (85 ft. lbs.) torque.
the rear of the engine. (8) Install oil pump.
(5) Apply 5 mm (0.20 in) drop of Mopart Gasket (9) Apply Mopart Silicone Rubber Adhesive Seal-
Maker, or equivalent, on each side of the rear main ant, or equivalent, at bearing cap to block joint to
bearing cap (Fig. 77). DO NOT over apply sealant or provide cap to block and oil pan sealing (Fig. 78).
allow the sealant to contact the rubber seal. Assem- Apply enough sealant until a small amount is
ble bearing cap to cylinder block immediately after squeezed out. Withdraw nozzle and wipe excess seal-
sealant application. Be sure the white paint faces ant off the oil pan seal groove.
toward the rear of the engine. (10) Immediately install the oil pan.
(6) To align the bearing cap, use cap slot, align-
ment dowel and cap bolts. DO NOT remove excess ENGINE CORE OIL AND CAMSHAFT PLUGS
material after assembly. DO NOT strike rear cap Engine core plugs have been pressed into the oil
more than 2 times for proper engagement. galleries behind the camshaft thrust plate (Fig. 79).
(7) Install the rear main bearing cap with cleaned This will reduce internal leakage and help maintain
and oiled cap bolts. Alternately tighten ALL cap bolts higher oil pressure at idle.
to 115 N·m (85 ft. lbs.) torque.
(8) Install oil pump.
(9) Apply Mopart Silicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 78).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(10) Immediately install the oil pan.

LOWER SEAL
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Remove the rear main bearing cap and discard
the old lower seal.

INSTALLATION
(1) Clean the rear main cap mating surfaces Fig. 79 Location of Cup Plugs in Oil Galleries
including the oil pan gasket groove. 1 – CUP PLUGS
(2) Carefully install a new upper seal (refer to
Upper Seal Replacement - Crankshaft Installed pro- REMOVAL
cedure above). (1) Using a blunt tool such as a drift or a screw-
(3) Lightly oil the new lower seal lips with engine driver and a hammer, strike the bottom edge of the
oil. cup plug (Fig. 80).
(4) Install a new lower seal in bearing cap with (2) With the cup plug rotated, grasp firmly with
the white paint facing the rear of engine. pliers or other suitable tool and remove plug (Fig.
(5) Apply 5 mm (0.20 in) drop of Mopart Gasket 80).
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 77). DO NOT over apply sealant or

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 DN 5.9L ENGINE 9 - 181
REMOVAL AND INSTALLATION (Continued)

Fig. 80 Core Hole Plug Removal

1 – CYLINDER BLOCK Fig. 81 Oil Pressure Relief Valve
2 – REMOVE PLUG WITH PLIERS 1 – OIL PUMP ASSEMBLY
3 – STRIKE HERE WITH HAMMER 2 – COTTER PIN
4 – DRIFT PUNCH 3 – RELIEF VALVE
5 – CUP PLUG 4 – RETAINER CAP
5 – SPRING

INSTALLATION
Thoroughly clean inside of cup plug hole in cylin- (2) Remove oil pump cover (Fig. 82).
der block or head. Be sure to remove old sealer. (3) Remove pump outer rotor and inner rotor with
Be certain the new plug is cleaned of all oil or shaft (Fig. 82).
grease. (4) Wash all parts in a suitable solvent and inspect
(1) Coat edges of plug and core hole with Mopart carefully for damage or wear.
Gasket Maker, or equivalent.

CAUTION: DO NOT drive cup plug into the casting,

as restricted coolant flow can result and cause seri-
ous engine problems.

(2) Using proper plug drive, drive cup plug into

hole. The sharp edge of the plug should be at least
0.50 mm (0.020 in.) inside the lead-in chamfer.
(3) It is not necessary to wait for curing of the
sealant. The cooling system can be filled and the
vehicle placed in service immediately.

Fig. 82 Oil Pump

DISASSEMBLY AND ASSEMBLY 1 – INNER ROTOR AND SHAFT
2 – BODY
OIL PUMP 3 – DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 – COTTER PIN
DISASSEMBLE 5 – RETAINER CAP
6 – SPRING
(1) Remove the relief valve as follows:
7 – RELIEF VALVE
(a) Remove cotter pin. Drill a 3.175 mm (1/8
8 – LARGE CHAMFERED EDGE
inch) hole into the relief valve retainer cap and 9 – BOLT
insert a self-threading sheet metal screw. 10 – COVER
(b) Clamp screw into a vise and while support- 11 – OUTER ROTOR
ing oil pump, remove cap by tapping pump body
using a soft hammer. Discard retainer cap and
remove spring and relief valve (Fig. 81).

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 9 - 182 5.9L ENGINE DN
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLE Check the pistons for taper and elliptical shape
(1) Install pump rotors and shaft, using new parts before they are fitted into the cylinder bore (Fig. 83).
as required.
(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N·m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling
rotor cavity with engine oil.

CLEANING AND INSPECTION

CYLINDER HEAD COVER
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.

INSPECTION
Fig. 83 Piston Measurements
Inspect cover for distortion and straighten, if nec-
1 – 49.53 mm
essary. (1.95 IN.)
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
OIL PAN
CYLINDER HEAD ASSEMBLY
CLEANING
CLEANING Clean the block and pan gasket surfaces.
Clean all surfaces of cylinder block and cylinder Trim or remove excess sealant film in the rear
heads. main cap oil pan gasket groove. DO NOT remove
Clean cylinder block front and rear gasket surfaces the sealant inside the rear main cap slots.
using a suitable solvent. If present, trim excess sealant from inside the
engine.
INSPECTION Clean oil pan in solvent and wipe dry with a clean
Inspect all surfaces with a straightedge if there is cloth.
any reason to suspect leakage. If out-of-flatness Clean oil screen and pipe thoroughly in clean sol-
exceeds 0.00075 mm/mm (0.00075 inch/inch) times vent. Inspect condition of screen.
the span length in inches in any direction, either
replace head or lightly machine the head surface. INSPECTION
FOR EXAMPLE: A 305 mm (12 inch) span is Inspect oil drain plug and plug hole for stripped or
0.102 mm (0.004 inch) out-of-flat. The allowable out- damaged threads. Repair as necessary.
of-flat is 305 X 0.00075 (12 X 0.00075) equals 0.23 Inspect oil pan mounting flange for bends or distor-
mm (0.009 inch). This amount of out-of-flat is accept- tion. Straighten flange, if necessary.
able.
The cylinder head surface finish should be OIL PUMP
1.78-3.00 microns (70-125 microinches).
INSPECTION
PISTON AND CONNECTING ROD ASSEMBLY Mating surface of the oil pump cover should be
smooth. Replace pump assembly if cover is scratched
INSPECTION or grooved.
Check the crankshaft connecting rod journal for Lay a straightedge across the pump cover surface
excessive wear, taper and scoring. (Fig. 84). If a 0.038 mm (0.0015 inch) feeler gauge
Check the cylinder block bore for out-of-round, can be inserted between cover and straightedge,
taper, scoring and scuffing. pump assembly should be replaced.

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 DN 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 mm mm mm (in.)
(in.) (in.) (in.)

A — — — —

B 101.580 101.592 101.605 101.618

(3.9992) (3.9997) (4.0002) (4.0007)

C 101.592 101.605 101.618 101.630

(3.9997) (4.0002) (4.0007) (4.0012) Fig. 84 Checking Oil Pump Cover Flatness
1 – COVER
D 101.605 101.618 101.630 101.643
2 – STRAIGHT EDGE
(4.0002) (4.0007) (4.0012) (4.0017) 3 – FEELER GAUGE

E — — — —

DESCRIPTION SPECIFICATION

PISTON PIN 25.007 - 25.015 mm

BORE (.9845 -.9848 in.)

RING GROOVE
HEIGHT
OIL RAIL 4.033 - 4.058 mm
(.1588 -.1598 in.)
COMPRESSION 1.529 - 1.554 mm
RAIL
(.0602 -.0612 in.)

TOTAL FINISHED 470.8 6 2 grams Fig. 85 Measuring Outer Rotor Thickness

WEIGHT (16.607 6.0706 ounces)

Measure thickness and diameter of OUTER rotor.

If outer rotor thickness measures 20.9 mm (0.825
inch) or less or if the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 85).
If inner rotor measures 20.9 mm (0.825 inch) or
less, replace inner rotor and shaft assembly (Fig. 86).

Fig. 86 Measuring Inner Rotor Thickness

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 9 - 184 5.9L ENGINE DN
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.

Fig. 89 Measuring Clearance Over Rotors

1 – STRAIGHT EDGE
2 – FEELER GAUGE

Fig. 87 Measuring Outer Rotor Clearance in

Housing Inspect oil pressure relief valve plunger for scoring
1 – PUMP BODY and free operation in its bore. Small marks may be
2 – OUTER ROTOR removed with 400-grit wet or dry sandpaper.
3 – FEELER GAUGE The relief valve spring has a free length of approx-
imately 49.5 mm (1.95 inches). The spring should
test between 19.5 and 20.5 pounds when compressed
Install inner rotor and shaft into pump body. If
to 34 mm (1-11/32 inches). Replace spring that fails
clearance between inner and outer rotors is 0.203
to meet these specifications (Fig. 90).
mm (0.008 inch) or more, replace shaft and both
If oil pressure was low and pump is within specifi-
rotors (Fig. 88).
cations, inspect for worn engine bearings or other
reasons for oil pressure loss.

Fig. 88 Measuring Clearance Between Rotors

1 – OUTER ROTOR Fig. 90 Proper Installation of Retainer Cap
2 – FEELER GAUGE 1 – RETAINER CAP
3 – INNER ROTOR 2 – CHAMFER
3 – COTTER KEY

Place a straightedge across the face of the pump,

between bolt holes. If a feeler gauge of 0.102 mm
(0.004 inch) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig.
89).

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 DN 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-
round and taper with Cylinder Bore Indicator Tool (4.00 x 3.58 in.)
C-119. The cylinder block should be bored and honed Displacement 5.9L (360 c.i.)
with new pistons and rings fitted if: Compression Ratio 9.1:1
• The cylinder bores show more than 0.127 mm
Firing Order 1–8–4–3–6–5–7–2
(0.005 inch) out-of-round.
• The cylinder bores show a taper of more than Lubrication Pressure Feed –
0.254 mm (0.010 inch). Full Flow Filtration
• The cylinder walls are badly scuffed or scored.
Cooling System Liquid Cooled –
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec- Forced Circulation
ified clearances may be maintained. Cylinder Block Cast Iron
Refer to Standard Service Procedures in the begin- Cylinder Head Cast Iron
ning of this Group for the proper honing of cylinder
bores. Crankshaft Nodular Iron
Camshaft Nodular Cast Iron
INTAKE MANIFOLD Combustion Chambers Wedge -
High Swirl Valve
CLEANING
Shrouding
Clean manifold in solvent and blow dry with com-
pressed air. Pistons Aluminum Alloy w/strut
Clean cylinder block front and rear gasket surfaces Connecting Rods Forged Steel
using a suitable solvent. Cylinder Compression 689.5 kPa
The plenum pan rail must be clean and dry (free of
all foreign material). Pressure (Min.) (100 psi)

INSPECTION DESCRIPTION SPECIFICATION

Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness CAMSHAFT
with a straightedge.
Bearing Diameter
EXHAUST MANIFOLD No. 1 50.800 – 50.825 mm
CLEANING (2.000 – 2.001 in.)
Clean mating surfaces on cylinder head and mani- No. 2 50.394 – 50.419 mm
fold, wash with solvent and blow dry with com- (1.984 – 1.985 in.)
pressed air.
No. 3 50.013 – 50.038 mm
INSPECTION (1.969 – 1.970 in.)
Inspect manifold for cracks, Inspect mating sur- No. 4 49.606 – 49.632 mm
faces of manifold for flatness with a straight edge. (1.953 – 1.954 in.)
Seal surfaces must be flat within 0.1 mm (0.004 inch)
overall. No. 5 39.688 – 39.713 mm
(1.5625 – 1.5635 in.)

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 9 - 186 5.9L ENGINE DN
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 – 1.983 in.) #1 Journal 0.0381 mm (0.0015 in.)
No. 3 49.962 – 49.987 mm Bearing Clearance
(1.967 – 1.968 in.) #2-5 Journals 0.013 – 0.051 mm
No. 4 49.555 – 49.581 mm (0.0005 – 0.002 in.)
(1.951 – 1.952 in.) Service Limit
No. 5 39.637 – 39.662 mm #2-5 Journals 0.064 mm (0.0025 in.)
(1.5605 – 1.5615 in.) End Play 0.051 – 0.178 mm
(0.002 – 0.007 in.)
Bearing to Journal
Clearance Service Limit 0.254 mm (0.010 in.)
Standard 0.0254 – 0.0762 mm CYLINDER BLOCK
(0.001 – 0.003 in.)
Cylinder Bore
Service Limit 0.127 mm
Diameter 101.60 – 101.65 mm
(0.005 in.)
(4.000 – 4.002 in.)
Camshaft End Play 0.051 – 0.254 mm
Out of Round (Max.) 0.025 mm (0.001 in.)
(0.002 – 0.010 in.)
Taper (Max.) 0.025 mm (0.001 in.)
CONNECTING RODS
Lifter Bore
Piston Pin Bore Diameter 24.966 - 24.978 mm Diameter 22.99 – 23.01 mm
(0.9829 - 0.9834 in.) (0.9051 – 0.9059 in.)
Side Clearance 0.152 - 0.356 mm
Distributor Drive
(0.006 - 0.014 in.)
Bushing—
CRANKSHAFT (Press Fit)
Bushing to Bore 0.0127 – 0.3556 mm
Rod Journal
Interference
Diameter 53.950 – 53.975 mm
(0.0005 – 0.0140 in.)
(2.124 – 2.125 in.)
Shaft to Bushing 0.0178 – 0.0686 mm
Out of Round (Max.) 0.0254 mm (0.001 in.) Clearance
Taper (Max.) 0.0254 mm (0.001 in.) (0.0007 – 0.0027 in.)
Bearing Clearance 0.013 – 0.056 mm
CYLINDER HEAD AND VALVES
(0.0005 – 0.0022 in.)
Service Limit 0.0762 mm (0.003 in.) Valve Seat
Angle 44.25° – 44.75°
Main Bearing Journal
Runout (Max.) 0.0762 mm (0.003 in.)
Diameter 71.361 – 71.387 mm
Width (Finish) – Intake 1.016 – 1.524 mm
(2.8095 – 2.8105 in.)
(0.040 – 0.060 in.)
Out of Round (Max.) 0.127 mm (0.001 in.)
Width (Finish) – Exhaust 1.524 – 2.032 mm
Taper (Max.) 0.0254 mm (0.001 in.)
(0.060 – 0.080 in.)

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 DN 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 – 0.0610 mm
Exhaust
(0.0011 – 0.0024 in.)
Length (Overall) – Intake 126.21 – 126.85 mm
Dry Lash 1.524 – 5.334 mm
(4.969 – 4.994 in.)
(0.060 – 0.210 in.)
Length (Overall) – 126.44 – 127.30 mm
Exhaust Push Rod Length 175.64 – 176.15 mm
(4.978 – 5.012 in.) (6.915 – 6.935 in.)
Lift (@ zero lash) – 10.414 mm (0.410 in.) OIL PRESSURE
Intake
Lift (@ zero lash) – 10.592 mm (0.417 in.) Curb Idle (Min.*) 41.4 kPa (6 psi)
Exhaust 3000 rpm 207 – 552 kPa (30 – 80
Stem Diameter – Intake 9.449 – 9.474 mm psi)
(0.372 – 0.373 in.) Oil Pressure Bypass
Valve—
Stem Diameter – Exhaust 9.423 – 9.449 mm
Setting 62 – 103 kPa (9 – 15 psi)
(0.371 – 0.372 in.)
Switch Actuating 34.5 – 48.3 kPa (5 – 7
Guide Bore 9.500 – 9.525 mm Pressure psi)
(0.374 – 0.375 in.) * If oil pressure is zero at curb idle, DO NOT RUN
Stem to Guide ENGINE.
Clearance—
OIL PUMP
Intake 0.0254 – 0.0762 mm
(0.001 – 0..003 in.) Clearance over Rotors 0.1016 mm (0.004 in.)
Stem to Guide (Max.)
Clearance— Cover Out of Flat (Max.) 0.0381 mm (0.0015 in.)
Exhaust 0.0508 – 0.1016 mm Inner Rotor Thickness 20.955 mm (0.825 in.)
(0.002 – 0.004 in.) (Min.)
Service Limit 0.4318 (0.017 in.) Outer Rotor Clearance 0.3556 mm (0.014 in.)
(Max.)
Valve Springs Outer Rotor Diameter 62.7126 mm (2.469 in.)
Free Length 49.962 mm (1.967 in.) (Min.)
Spring Tension – (valve 378 N @ 41.66 mm Outer Rotor Thickness 20.955 mm (0.825 in.)
closed) (Min.)
(85 lbs. @ 1.64 in.) Tip Clearance between
Spring Tension – (valve 890 N @ 30.89 mm Rotors—
open) (Max.) 0.2032 mm (0.008 in.)
(200 lbs. @ 1.212 in.)
Number of Coils 6.8
Installed Height 41.66 mm (1.64 in.)

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 9 - 188 5.9L ENGINE DN
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.)
Land Clearance (Diam.) 0.508 – 0.660 mm VALVE TIMING
(0.020 – 0.026 in.) Exhaust Valve
Piston Length 81.03 mm (3.19 in.) Closes (ATDC) 33°
Piston Ring Groove Opens (BBDC) 56°
Depth—
Duration 269°
#1&2 4.761 – 4.912 mm
Intake Valve
(0.187 – 0.193 in.)
Closes (ATDC) 62°
Piston Ring Groove
Opens (BBDC) 7°
Depth—
Duration 249°
#3 3.996 – 4.177 mm
Valve Overlap 41°
(0.157 – 0.164 in.)
Weight 582 – 586 grams OVERSIZE AND UNDERSIZE ENGINE
(20.53 – 20.67 oz.) COMPONENT MARKINGS CHART

PISTON PINS
ITEM U/S IDENTI- IDENTI-
Clearance in Piston 0.006 – 0.019 mm (O/S) FICATION FICATION
LOCATION
(0.00023 – 0.00074 in.)
Crank- 0.0254 R or M M-2-3 Milled flat on
Diameter 25.007 – 25.015 mm
shaft mm ect. No. 8
(0.9845 – 0.9848 in.) Journals (0.001 (indicating crankshaft
End Play NONE in.) U/S No. 2 and 3 counterweight.
Length 67.8 – 68.3 mm main bearing
journal)
(2.67 – 2.69 in.) and/or R-1-4
PISTON RINGS ect.
(indicating
Ring Gap No. 1 and 4
Compression Ring (Top) 0.30 – 0.55 mm connecting
rod journal)
(0.012 – 0.022 in.)
Hydraulic 0.2032 l Diamond-
Compression Ring (2nd) 0.55 – 0.80 mm Tappets mm shaped stamp
(0.022 – 0.031 in.) (0.008 top pad - front
Oil Control (Steel Rails) 0.381 – 1.397 mm in.) of engine and
(O/S) flat ground on
(0.015 – 0.055 in.)
outside
Ring Side Clearance surface of
Compression Rings 0.040 – 0.085 mm each O/S
(0.0016 – 0.0033 in.) tappet bore.

Oil Ring (Steel Rails) 0.05 – 0.21 mm Valve 0.127 X Milled pad
Stems mm adjacent to
(0.002 – 0.008 in.) (0.005 two tapped
Ring Width in.) holes (3/8 in.)
Compression rings 1.530 – 1.555 mm (O/S) on each end
of cylinder
(0.060 – 0.061 in.)
head.

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 DN 5.9L ENGINE 9 - 189
SPECIFICATIONS (Continued)

SPECIFICATIONS DESCRIPTION N·m Ft. In.

TORQUE CHART 5.9L ENGINE
Lbs. Lbs.
Rear Insulator to 68 50 —
DESCRIPTION N·m Ft. In. Transmission—
Lbs. Lbs. Bolts (4WD)
Camshaft Sprocket—Bolt 68 50 — Rear Insulator Bracket—Bolts 68 50 —
Camshaft Thrust Plate—Bolts 24 — 210
(4WD Automatic)
Timing Chain Case Cover— 41 30 —
Rear Support Bracket to 41 30 —
Bolts
Crossmember Flange—Nuts
Connecting Rod Cap—Bolts 61 45 —
Rear Support Plate to 41 30 —
Main Bearing Cap—Bolts 115 85 —
Transfer
Crankshaft Pulley—Bolts 24 — 210
Case—Bolts
Cylinder Head—Bolts
Rocker Arm—Bolts 28 21 —
Step 1 68 50 —
Spark Plugs 41 30 —
Step 2 143 105 —
Starter Motor—Mounting Bolts 68 50 —
Cylinder Head Cover—Bolts 11 — 95
Thermostat Housing—Bolts 25 — 225
Engine Support Bracket to 41 30 —
Throttle Body—Bolts 23 — 200
Block—
Torque Converter Drive 31 — 270
Bolts (4WD) Plate—Bolts
Exhaust Manifold to Cylinder 34 25 — Transfer Case to Insulator 204 105 —
Head—
Mounting Plate—Nuts
Bolts/Nuts
Transmission Support 68 50 —
Flywheel—Bolts 75 55 — Bracket—
Front Insulator—Through 95 70 —
Bolts (2WD)
bolt/nut
Vibration Damper—Bolt 244 180 —
Front Insulator to Support
Bracket Water Pump to Timing Chain 41 30 —
—Stud Nut (4WD) 41 30 — Case Cover—Bolts
—Through Bolt/Nut (4WD) 102 75 —
Front Insulator to Block— 95 70 — SPECIAL TOOLS
Bolts (2WD)
Generator—Mounting Bolt 41 30 — 5.9L ENGINE
Intake Manifold—Bolts Refer to Procedure
Oil Pan—Bolts 24 — 215
Oil Pan—Drain Plug 34 25 —
Oil Pump—Attaching Bolts 41 30 —
Oil Pump Cover—Bolts 11 — 95
Rear Insulator to Bracket— 68 50 —
Through-Bolt (2WD)
Rear Insulator to 41 30 —
Crossmember Oil Pressure Gauge C-3292
Support Bracket—Nut (2WD)
Rear Insulator to 68 50 —
Crossmember—
Nuts (4WD)

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 9 - 190 5.9L ENGINE DN
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

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 DN 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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