Dodge Durango (DN). Manual — part 160

• If a leak occurs with the vehicle parked in a

steady light rain, flood the leak area with an open-
ended garden hose.

• If a leak occurs while driving at highway speeds

in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.

• If a leak occurs when the vehicle is parked on an

incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations refer to Group 0,
Lubrication and Maintenance, General Information
section.

WATER LEAK DETECTION

To detect a water leak point-of-entry, do a water

test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.

Some water leaks must be tested for a considerable

length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.

Locating the entry point of water that is leaking

into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.

MIRROR INSPECTION METHOD

When a leak point area is visually obstructed, use

a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.

BRIGHT LIGHT LEAK TEST METHOD

Some water leaks in the luggage compartment can

be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally

sealed location, water could enter through the open-
ing.

PRESSURIZED LEAK TEST METHOD

When a water leak into the passenger compart-

ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.

SERVICE PROCEDURES

BODY LUBRICATION

All mechanisms and linkages should be lubricated

when necessary. This will maintain ease of operation
and provide protection against rust and excessive
wear. The weatherstrip seals should be lubricated to
prolong their life as well as to improve door sealing.

All applicable exterior and interior vehicle operat-

ing mechanisms should be inspected and cleaned.
Pivot/sliding contact areas on the mechanisms should
then be lubricated.

(1) When necessary, lubricate the operating mech-

anisms with the specified lubricants.

(2) Apply silicone lubricant to a cloth and wipe it

on door seals to avoid over-spray that can soil pas-
senger’s clothing.

(3) Before

applying

lubricant,

the

component

should be wiped clean. After lubrication, any excess
lubricant should be removed.

(4) The hood latch, latch release mechanism, latch

striker, and safety latch should be lubricated period-
ically.

(5) The door lock cylinders should be lubricated

twice each year (preferably autumn and spring).

• Spray a small amount of lock cylinder lubricant

directly into the lock cylinder.

• Apply a small amount to the key and insert it

into the lock cylinder.

• Rotate it to the locked position and then back to

the unlocked position several times.

• Remove the key. Wipe the lubricant from it with

a clean cloth to avoid soiling of clothing.

HEAT STAKING

(1) Remove trim panel.

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DIAGNOSIS AND TESTING (Continued)

(2) Bend or move the trim panel components at

the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.

(3) Heat stake the components.

(a) If the heat staked or component seam loca-

tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt

the

material

securing

the

components

together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.

(b) If the heat staked material is broken or miss-

ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the

repair.

(5) Install trim panel.

REMOVAL AND INSTALLATION

GRILLE

REMOVAL

(1) Release primary hood latch.
(2) Release hood safety catch and open hood.
(3) Remove screws attaching bottom of grille to

grille mounting bracket.

(4) Remove nuts attaching grille to hood (Fig. 1).
(5) Separate grille from vehicle.

INSTALLATION

(1) Position grille on hood.
(2) Install nuts attaching grille to hood.
(3) Install screws attaching bottom of grille to

grille mounting bracket.

(4) Close hood.

HOOD

REMOVAL

(1) Release primary hood latch.
(2) Release hood safety catch and open hood.
(3) Disconnect the under hood lamp wire connec-

tor.

(4) Mark all nut and hinge attachment locations

with a grease pencil or other suitable device to pro-
vide reference marks for installation.

(5) Remove the top nuts attaching hood to hinge

and loosen the bottom nuts until they can be
removed by hand (Fig. 2).

(6) With assistance of a helper, support the hood at

the opposite side of the vehicle.

(7) Remove the bottom nuts and separate the hood

from the vehicle.

INSTALLATION

(1) With assistance of a helper, position the hood

on hinges.

(2) Align all marks and install the nuts. The hood

should be aligned to 5 mm (0.2 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers.

(3) Connect the under hood lamp wire connector.
(4) Close hood and adjust as necessary.

Fig. 1 Grille

1 – GRILLE
2 – GRILLE MOUNTING BRACKET

Fig. 2 Hood

1 – HOOD
2 – HOOD HINGE

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SERVICE PROCEDURES (Continued)

HOOD SILENCER PAD

REMOVAL

(1) Raise the hood.
(2) Remove the retainers attaching the silencer

pad to the hood (Fig. 3).

(3) Remove the silencer pad from the hood.

INSTALLATION

(1) Position the silencer pad on the hood.
(2) Install the retainers attaching the silencer pad

to the hood.

(3) Close the hood.

HOOD HINGE

REMOVAL

(1) Open hood and support the side that requires

hinge replacement.

(2) Remove cowl grille.
(3) Mark all bolt and hinge attachment locations

with a grease pencil or other suitable device to pro-
vide reference marks for installation.

(4) Remove the nuts attaching the hinge to the

hood (Fig. 4).

(5) Remove the bolts attaching the hinge to the

inner fender (Fig. 4).

(6) Separate hinge from vehicle.

INSTALLATION

(1) If necessary, paint new hinge before installa-

tion.

(2) Position the hinge on the vehicle and align all

marks.

(3) Install the bolts attaching the hinge to the

inner fender.Tighten the bolts to 28.2N·m (250 in.
lbs.) torque.

(4) Install the nuts attaching the hinge to the

hood. Tighten the nuts to 22.6 N·m (200 in. lbs )
torque.

(5) Install cowl grille.
(6) Remove support and verify hood operation. The

hood should be aligned to 5 mm (0.2 in.) gap to the
front fenders.

HOOD SAFETY LATCH

REMOVAL

(1) Release primary hood latch.
(2) Release hood safety catch and open hood.
(3) Remove bolts attaching hood safety latch to

hood (Fig. 5).

(4) Separate safety latch from hood.

INSTALLATION

(1) Position safety latch on hood.
(2) Install bolts attaching safety latch to hood.

Tighten the bolts to 9.6 N·m (85 in. lbs.) torque.

(3) Close hood and verify operation. Adjust as nec-

essary.

HOOD LATCH STRIKER

The hood latch striker is incorporated with the

hood safety latch. Refer to the Hood Safety Latch
paragraph in this group for service procedures

Fig. 3 Hood Silencer Pad

1 – HOOD
2 – RETAINER
3 – HOOD SILENCER PAD

Fig. 4 Hood Hinge

1 – HOOD
2 – HOOD HINGE

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REMOVAL AND INSTALLATION (Continued)

HOOD LATCH

REMOVAL

(1) Release primary hood latch.
(2) Release hood safety catch and open hood.
(3) Using a grease pencil, mark latch position for

installation alignment.

(4) Remove bolts attaching hood latch to radiator

closure panel crossmember (Fig. 6).

(5) Separate hood latch from crossmember.
(6) Disconnect release cable from hood latch (Fig.

7).

INSTALLATION

(1) Connect release cable to hood latch.

(2) Position hood latch on crossmember. Ensure

the bottom flange of hood latch (Fig. 7) is secured
around the latch bracket (Fig. 6).

(3) Install the bolts attaching hood latch to radia-

tor closure panel crossmember. Tighten the bolts to
10.7 N·m (80 in. lbs.) torque.

(4) Close hood.
(5) Adjust latch as necessary.

HOOD RELEASE CABLE

REMOVAL

(1) Release primary hood latch.
(2) Release hood safety catch and open hood.
(3) Remove hood latch.
(4) Disconnect release cable from hood latch (Fig.

7).

(5) Detach the release cable and the retainer clips

in the engine compartment.

(6) Separate the release cable grommet from the

dash panel hole.

(7) From the inside of the vehicle, remove the

screws attaching the hood release handle to the bot-
tom of the instrument panel (Fig. 8).

(8) Pull/route the hood release cable through the

dash panel hole and remove it via the inside of the
vehicle.

INSTALLATION

NOTE: If replacement hood latch is also being
installed, ensure that it is thoroughly lubricated.

(1) From inside the vehicle, pull/route the hood

release cable through the dash panel hole and into
the engine compartment.

Fig. 5 Hood Safety Latch

1 – HOOD
2 – SAFETY LATCH
3 – HINGE

Fig. 6 Hood Latch

1 – RADIATOR CLOSURE PANEL
2 – HOOD RELEASE CABLE
3 – HOOD LATCH
4 – LATCH BRACKET

Fig. 7 Hood Release Cable

1 – HOOD RELEASE CABLE
2 – HOOD LATCH
3 – BOTTOM FLANGE

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REMOVAL AND INSTALLATION (Continued)