Dodge Durango (DN). Manual — part 452
Fig.
4
Oil
Lubrication
System
9 - 138
5.9L ENGINE
DN
DESCRIPTION AND OPERATION (Continued)
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds are constructed of cast iron
and are LOG type with balanced flow (Fig. 5). One
exhaust manifold is attached to each cylinder head.
OPERATION
The exhaust manifolds collect the engine exhaust
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipes attached to the
manifolds.
INTAKE MANIFOLD
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
must be used when sealing the gaskets to ensure
that excess sealant does not enter the intake runners
causing a restriction. Whenever the intake manifold
is removed inspect the plenum pan for evidence of
excess oil buildup, this condition indicates that the
plenum pan gasket is leaking.
OPERATION
The intake manifold, meters and delivers air to the
combustion chambers allowing the fuel delivered by
the fuel injectors to ignite, thus producing power.
1 – OIL DEFLECTOR TAB
2 – BOLT
3 – ROCKER ARM PIVOT
4 – ROCKER ARM
5 – DRIP OILING FOR VALVE TIP
6 – CYLINDER HEAD BOSS
7 – TO MAIN BEARINGS
8 – TO CAMSHAFT BEARINGS
9 – ROCKER ARM
10 – HOLLOW PUSH ROD
11 – TAPPET
12 – TO CONNECTING ROD BEARINGS
13 – OIL INTAKE
14 – OIL PUMP
15 – OIL FILTER
16 – CRANKSHAFT
17 – FROM OIL PUMP
18 – OIL TO FILTER
19 – OIL FROM FILTER TO SYSTEM
20 – PASSAGE TO CAMSHAFT REAR BEARING
21 – RIGHT OIL GALLERY
22 – PLUG
23 – OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT
24 – OIL SUPPLY VIA HOLLOW PUSH ROD SUPPLY IS FROM
OIL GALLERY METERED THROUGH HYDRAULIC TAPPET
25 – OIL SUPPLY FROM HOLLOW PUSH ROD
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
2 – FUEL RAIL MOUNTING BOLTS
3 – FUEL RAIL CONNECTING HOSES
DN
5.9L ENGINE
9 - 139
DESCRIPTION AND OPERATION (Continued)
CYLINDER HEAD COVER GASKET
DESCRIPTION
The cylinder head cover gasket is a steel-backed
silicone gasket, designed for long life usage (Fig. 7).
OPERATION
The steel-backed silicone gasket is designed to seal
the cylinder head cover for long periods of time
through extensive heat and cold, without failure. The
gasket is designed to be reusable.
CYLINDER HEAD
DESCRIPTION
The cast iron cylinder heads (Fig. 8) are mounted
to the cylinder block using ten bolts. The spark plugs
are located in the peak of the wedge between the
valves.
OPERATION
The cylinder head closes the combustion chamber
allowing the pistons to compress the air fuel mixture
to the correct ratio for ignition. The valves located in
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)
wafer interia welded to the tip for durability. These
valves are not splayed.
ENGINE OIL PAN
DESCRIPTION
The stamped steel engine oil pan is located at the
bottom of the engine, and contains a drain plug for
draining the engine oil.
OPERATION
The oil pan holds the engine oil and seals and pro-
tects the engine lower components from contami-
nates.
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.
PISTON AND CONNECTING ROD
DESCRIPTION
The pistons are made of aluminum and have three
ring grooves, the top two grooves are for the compres-
sion rings and the bottom groove is for the oil control
ring. The connecting rods are forged steel and are
coined prior to heat treat. The piston pins are press
fit.
Fig. 7 Cylinder Head Cover Gasket V-8 Gas Engines
1 – CYLINDER HEAD COVER GASKET
Fig. 8 Cylinder Head Assembly—V-8 Gas Engines
1 – EXHAUST VALVE
2 – SPARK PLUGS
3 – EXHAUST VALVES
4 – SPARK PLUGS
5 – EXHAUST VALVE
6 – INTAKE VALVES
7 – INTAKE VALVES
9 - 140
5.9L ENGINE
DN
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.
OPERATION
The main bearings encircle the crankshaft main
bearing journals, this aligns the crankshaft to the
centerline of the engine and allows the crankshaft to
turn without wobbling or shaking therefore eliminat-
ing vibration. The main bearings are available in
standard and undersizes.
CRANKSHAFT
DESCRIPTION
The crankshaft is of a cast nodular steel splayed
type design, with five main bearing journals. The
crankshaft is located at the bottom of the engine
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.
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
(e.g., engine idles rough and stalls).
Refer to the Service Diagnosis—Mechanical Chart
and the Service Diagnosis—Performance Chart, for
possible causes and corrections of malfunctions. Refer
to FUEL SYSTEM for the fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
• Cylinder Compression Pressure Test
• Cylinder Combustion Pressure Leakage Test
• Cylinder Head Gasket Failure Diagnosis
• Intake Manifold Leakage Diagnosis
• Lash Adjuster (Tappet) Noise Diagnosis
• Engine Oil Leak Inspection
Fig. 9 Main Bearing Orientation
Fig. 10 Crankshaft with Journal Size Identification
DN
5.9L ENGINE
9 - 141
DESCRIPTION AND OPERATION (Continued)
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