Dodge Durango (DN). Manual — part 459

(2) Disconnect closed ventilation system and evap-

oration control system from cylinder head cover.

(3) Remove the air inlet hose.
(4) Remove cylinder head cover and gasket. The

gasket may be used again.

INSTALLATION

(1) The cylinder head cover gasket can be used

again. Install the gasket onto the head rail.

(2) Position the cylinder head cover onto the gas-

ket. Tighten the bolts to 11 N·m (95 in. lbs.) torque.

(3) Install closed crankcase ventilation system and

evaporation control system.

(4) Install the air inlet hose.
(5) Connect the negative cable to the battery.

ROCKER ARMS AND PUSH RODS

REMOVAL

(1) Remove cylinder head cover and gasket. Refer

to Cylinder Head Cover in this section for correct
procedure.

(2) Remove the rocker arm bolts and pivots (Fig.

49). Place them on a bench in the same order as
removed.

(3) Remove the push rods and place them on a

bench in the same order as removed.

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.

CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).

(4) Install cylinder head cover.

VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE

(1) Remove the air cleaner.
(2) Remove cylinder head covers and spark plugs.
(3) Remove coil wire from distributor and secure to

good ground to prevent engine from starting.

(4) Using suitable socket and flex handle at crank-

shaft retaining bolt, turn engine so the No.1 piston is
at TDC on the compression stroke.

(5) Remove rocker arms.
(6) With air hose attached to an adapter installed

in No.1 spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.

(7) Using

Valve

Spring

Compressor

Tool

MD-998772A with adaptor 6716A, compress valve
spring and remove retainer valve locks and valve
spring.

(8) Install seals on the exhaust valve stem and

position down against valve guides.

(9) The intake valve stem seals should be pushed

firmly and squarely over the valve guide using the
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.
(15) Road test vehicle.

Fig. 48 Cylinder Head Cover Gasket

1 – CYLINDER HEAD COVER GASKET

Fig. 49 Rocker Arms

1 – ROCKER ARMS
2 – CYLINDER HEAD

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5.9L ENGINE

DN

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-
down cables.

(10) Remove distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect heat indicator sending unit wire.
(13) Disconnect heater hoses and bypass hose.
(14) Remove cylinder head covers and gaskets.
(15) Remove intake manifold and throttle body as

an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.

(16) Remove exhaust manifolds.
(17) Remove rocker arm assemblies and push rods.

Identify to ensure installation in original locations.

(18) Remove the head bolts from each cylinder

head and remove cylinder heads. Discard the cylin-
der head gasket.

(19) Remove spark plugs.

INSTALLATION

(1) Position the new cylinder head gaskets onto

the cylinder block.

(2) Position the cylinder heads onto head gaskets

and cylinder block.

(3) Starting at top center, tighten all cylinder head

bolts, in sequence, to 68 N·m (50 ft. lbs.) torque (Fig.
50). Repeat procedure, tighten all cylinder head bolts
to 143 N·m (105 ft. lbs.) torque. Repeat procedure to
confirm that all bolts are at 143 N·m (105 ft. lbs.)
torque.

CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.

(4) Install push rods and rocker arm assemblies in

their original position. Tighten the bolts to 28 N·m
(21 ft. lbs.) torque.

(5) Install the intake manifold and throttle body

assembly.

(6) Install exhaust manifolds. Tighten the bolts

and nuts to 34 N·m (25 ft. lbs.) torque.

(7) Adjust spark plugs to specifications. Refer to

IGNITION SYSTEM. Install the plugs and tighten to
41 N·m (30 ft. lbs.) torque.

(8) Install coil wires.
(9) Connect heat indicator sending unit wire.
(10) Connect the heater hoses and bypass hose.
(11) Install distributor cap and wires.
(12) Connect the accelerator linkage and if so

equipped, the speed control and transmission kick-
down cables.

(13) Install the fuel supply line.
(14) Install the generator and drive belt. Tighten

generator mounting bolt to 41 N·m (30 ft. lbs.)
torque.

(15) Install

the

intake

manifold-to-generator

bracket support rod. Tighten the bolts.

(16) Place the cylinder head cover gaskets in posi-

tion and install cylinder head covers. Tighten the
bolts to 11 N·m (95 in. lbs.) torque.

(17) Install closed crankcase ventilation system.
(18) Connect the evaporation control system.
(19) Install the air cleaner assembly and air inlet

hose.

(20) Install the heat shields. Tighten the bolts to

41 N·m (30 ft. lbs.) torque.

(21) Fill cooling system.
(22) Connect the battery negative cable.

VALVES AND VALVE SPRINGS

REMOVAL

(1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring

Compressor Tool MD- 998772A.

(3) Remove valve retaining locks, valve spring

retainers, valve stem seals and valve springs.

Fig. 50 Cylinder Head Bolt Tightening Sequence

DN

5.9L ENGINE

9 - 167

REMOVAL AND INSTALLATION (Continued)

(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

(1) Coat valve stems with lubrication oil and insert

them in cylinder head.

(2) If valves or seats are reground, check valve

stem height. If valve is too long, replace cylinder
head.

(3) Install new seals on all valve guides. Install

valve springs and valve retainers.

(4) Compress valve springs with Valve Spring

Compressor Tool MD-998772A, install locks and
release tool. If valves and/or seats are ground, mea-
sure the installed height of springs. Make sure the
measurement is taken from bottom of spring seat in
cylinder head to the bottom surface of spring
retainer. If spacers are installed, measure from the
top of spacer. If height is greater than 42.86 mm
(1-11/16 inches), install a 1.587 mm (1/16 inch)
spacer in head counterbore. This should bring spring
height back to normal 41.27 to 42.86 mm (1-5/8 to
1-11/16 inch).

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.

If all tappets are to be removed, identify tappets to
ensure installation in original location.

INSTALLATION

(1) If the tappet or bore in cylinder block is scored,

scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet.

(2) Lubricate tappets.
(3) Install tappets and push rods in their original

positions. Ensure that the oil feed hole in the side of
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,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.

VIBRATION DAMPER

REMOVAL

(1) Disconnect the battery negative cable.
(2) Remove the cooling system fan.
(3) Remove the cooling fan shroud.
(4) Remove the accessory drive belt. Refer to

COOLING SYSTEM.

(5) Remove vibration damper bolt and washer from

end of crankshaft.

(6) Position Special Tool 8513 Insert into the

crankshaft nose.

(7) Install Special Tool 1026 Three Jaw Puller onto

the vibration damper (Fig. 51).

(8) Pull vibration damper off of the crankshaft.

INSTALLATION

CAUTION: Thoroughly remove any contaminants
from the crankshaft nose and the vibration damper
bore. Failure to do so can cause sever damage to
the crankshaft.

(1) Position the vibration damper onto the crank-

shaft.

Fig. 51 Vibration Damper Removal

1 – SPECIAL TOOL 8513 INSERT
2 – SPECIAL TOOL 1026

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5.9L ENGINE

DN

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).

(3) Install the crankshaft bolt and washer. Tighten

the bolt to 244 N·m (180 ft. lbs.) torque.

(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).

(6) Remove vibration damper.
(7) Remove fuel lines (refer to Group 14, Fuel Sys-

tem).

(8) Loosen oil pan bolts and remove the front bolt

at each side.

(9) Remove the cover bolts.
(10) Remove chain case cover and gasket using

extreme caution to avoid damaging oil pan gasket.

(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. 53).

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.
Use a small amount of Mopar Silicone Rubber Adhe-
sive Sealant, or equivalent, at the joint between tim-
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

Front Oil Seal Installation Tool 6635 (Fig. 54). Seat
the oil seal in the groove of the tool.

(5) Position the seal and tool onto the crankshaft

(Fig. 55).

(6) Tighten the 4 lower chain case cover bolts to

13N·m (10 ft.lbs.) to prevent the cover from tipping
during seal installation.

(7) Using the vibration damper bolt, tighten the

bolt to draw the seal into position on the crankshaft
(Fig. 56).

(8) Loosen the 4 bolts tightened in step 4 to allow

realignment of front cover assembly.

(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.

Fig. 52 Vibration Damper Installation

1 – SPECIAL TOOL C-3688

Fig. 53 Removal of Front Crankshaft Oil Seal

Fig. 54 Placing Oil Seal on Installation Tool 6635

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

DN

5.9L ENGINE

9 - 169

REMOVAL AND INSTALLATION (Continued)

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