Dodge Durango (DN). Manual — part 451

Distributor Bushing Puller C-3052

Distributor Bushing Driver/Burnisher C-3053

Piston Ring Compressor C-385

Crankshaft Main Bearing Remover C-3059

Cylinder Bore Gauge C-119

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5.2L ENGINE

DN

SPECIAL TOOLS (Continued)

5.9L ENGINE

TABLE OF CONTENTS

page

page

DESCRIPTION AND OPERATION

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . 136
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 139
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 139
CYLINDER HEAD COVER GASKET . . . . . . . . . . 140
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 140
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 140
ENGINE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . 140
CRANKSHAFT OIL SEALS . . . . . . . . . . . . . . . . . 140
PISTON AND CONNECTING ROD . . . . . . . . . . . 140
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 141
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 141

DIAGNOSIS AND TESTING

ENGINE DIAGNOSIS—INTRODUCTION. . . . . . . 141
SERVICE DIAGNOSIS—GASOLINE ENGINES . . 142
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . 145
CYLINDER COMPRESSION PRESSURE TEST . 145
CYLINDER HEAD GASKET FAILURE

DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . 146

CYLINDER COMBUSTION PRESSURE

LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 146

INSPECTION (ENGINE OIL LEAKS IN

GENERAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

REAR SEAL AREA LEAKS—INSPECTION . . . . . 147
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 148
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . 148

SERVICE PROCEDURES

FORM-IN-PLACE GASKETS . . . . . . . . . . . . . . . . 149
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . 149
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
REPAIR DAMAGED OR WORN THREADS . . . . . 151
CYLINDER BORE—HONING . . . . . . . . . . . . . . . 152
HYDROSTATIC LOCK. . . . . . . . . . . . . . . . . . . . . 152
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . 153
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 153
MEASURING TIMING CHAIN STRETCH . . . . . . . 155
PISTONS—FITTING . . . . . . . . . . . . . . . . . . . . . . 156
PISTON RINGS—FITTING . . . . . . . . . . . . . . . . . 156
CONNECTING ROD BEARINGS—FITTING. . . . . 157
CRANKSHAFT MAIN BEARINGS—FITTING . . . . 157

REMOVAL AND INSTALLATION

ENGINE FRONT MOUNTS . . . . . . . . . . . . . . . . . 158

ENGINE REAR SUPPORT . . . . . . . . . . . . . . . . . 160
ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . 161
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 163
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 165
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 165
ROCKER ARMS AND PUSH RODS . . . . . . . . . . 166
VALVE SPRING AND STEM SEAL

REPLACEMENT-IN VEHICLE . . . . . . . . . . . . . 166

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 167
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 167
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 168
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . 168
TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . 169
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 170
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . 172
DISTRIBUTOR DRIVE SHAFT BUSHING . . . . . . 172
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 174
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
PISTON AND CONNECTING ROD ASSEMBLY . . 175
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 176
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
CRANKSHAFT OIL SEAL—FRONT. . . . . . . . . . . 178
CRANKSHAFT OIL SEALS—REAR. . . . . . . . . . . 179
ENGINE CORE OIL AND CAMSHAFT PLUGS . . 180

DISASSEMBLY AND ASSEMBLY

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

CLEANING AND INSPECTION

CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 182
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . 182
PISTON AND CONNECTING ROD ASSEMBLY . . 182
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 185
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 185
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 185

SPECIFICATIONS

5.9L ENGINE SPECIFICATIONS . . . . . . . . . . . . . 185
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 189

SPECIAL TOOLS

5.9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

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5.9L ENGINE

9 - 135

DESCRIPTION AND OPERATION

ENGINE

DESCRIPTION

The 5.9 Liter (360 CID) eight-cylinder engine is a

V-Type

lightweight,

single

cam,

overhead

valve

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).

The engine serial number is stamped into a

machined pad located on the left, front corner of the
cylinder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 2).

ENGINE LUBRICATION SYSTEM

DESCRIPTION

A gear-type positive displacement pump (Fig. 3) is

mounted at the underside of the rear main bearing
cap. The pump uses a pick-up tube and screen
assembly to gather engine oil from the oil pan.

OPERATION

The pump draws oil through the screen and inlet

tube from the sump at the rear of the oil pan. The oil
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.
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.

Fig. 1 Firing Order

Fig. 2 Engine Identification Number

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

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5.9L ENGINE

DN

The hydraulic valve tappets receive oil directly

from the main oil gallery. The camshaft bearings
receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the cam-
shaft sprocket to the timing chain. Oil drains back to
the oil pan under the No. 1 main bearing cap.

The oil supply for the rocker arms and bridged

pivot assemblies is provided by the hydraulic valve

tappets, which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components.
The oil then passes down through the push rod guide
holes and the oil drain-back passages in the cylinder
head, past the valve tappet area, and then returns to
the oil pan.

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5.9L ENGINE

9 - 137

DESCRIPTION AND OPERATION (Continued)