Dodge Durango (DN). Manual — part 426

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.

(9) Disconnect and remove ignition coil towers.
(10) Remove top oil dipstick tube retaining bolt

and ground strap.

(11) Bleed fuel system. Refer to FUEL SYSTEM.
(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.
(7) Connect throttle cable and speed control cable

to throttle body.

(8) Install fuel rail.
(9) Install ignition coil towers.

Fig. 48 Body Ground Strap—Right Side Removal /

Installation

1 – NUT
2 – A/C ACCUMULATOR
3 – GROUND STRAP

Fig. 49 Body Ground Strap—Left Side Removal /

Installation

1 – NUT
2 – GROUND STRAP
3 – BRAKE BOOSTER

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4.7L ENGINE

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REMOVAL AND INSTALLATION (Continued)

(10) Position and install heater hoses and tubes

onto intake manifold.

(11) Install the heater hoses to the heater core and

engine front cover.

(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

RIGHT EXHAUST MANIFOLD

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

starter aside.

(14) Remove lower exhaust manifold attaching fas-

teners.

(15) Remove exhaust manifold and gasket (Fig.

52). Manifold is removed from below the engine com-
partment.

Fig. 50 Heater Hoses and Tubes Removal /

Installation

1 – HEATER HOSES AND TUBES
2 – ROUTING/RETAINING CLIPS

Fig. 51 Intake Manifold Tightening Sequence

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4.7L ENGINE

DN

REMOVAL AND INSTALLATION (Continued)

INSTALLATION

(1) Install exhaust manifold and gasket from below

engine compartment.

(2) Install lower exhaust manifold fasteners. DO

NOT tighten until all fasteners are in place.

(3) Lower vehicle and install upper exhaust mani-

fold fasteners. Tighten all manifold bolts starting at
center and working outward to 25 N·m (18 ft. lbs.).

CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.

(4) Install exhaust manifold heat shield. Tighten

fasteners to 8 N·m (72 in. lbs.), then loosen 45
degrees.

(5) Install starter and fasteners.
(6) Connect exhaust pipe to manifold.
(7) Connect heater hoses at engine.
(8) Install fastener attaching A/C accumulator.

Fig. 52 Exhaust Manifold—Right

ITEM

DESCRIPTION

TORQUE

ITEM

DESCRIPTION

TORQUE

1

Stud (Qty 2)

25 N·m
(18 ft. lbs.)

4

Nut (Qty 2)

8 N·m
(72 in. lbs.), then
loosen 45
degrees

2

Bolt (Qty 4)

5

Nut (Qty 2)

3

Stud (Qty 2)

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4.7L ENGINE

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REMOVAL AND INSTALLATION (Continued)

(9) Install A/C compressor and fasteners.
(10) Install accessory drive belt.
(11) Install air cleaner assembly, resonator assem-

bly and air inlet hose.

(12) Install battery and connect cables.
(13) Fill cooling system.

LEFT EXHAUST MANIFOLD

REMOVAL

(1) Disconnect negative cable for battery.
(2) Hoist vehicle.
(3) Disconnect exhaust pipe at manifold.
(4) Lower vehicle.
(5) Remove the front two exhaust heat shield

retaining fasteners. Raise vehicle and remove the
fasteners at rear of heat shield.

(6) Remove heat shield (Fig. 53).
(7) Lower vehicle and remove the upper exhaust

manifold retaining bolts (Fig. 53).

(8) Raise vehicle and remove the lower exhaust

manifold retaining bolts (Fig. 53).

(9) Remove exhaust manifold and gasket (Fig. 53).

Manifold is removed from below the engine compart-
ment.

INSTALLATION

(1) Install exhaust manifold and gasket from below

engine compartment.

(2) Install lower exhaust manifold fasteners (Fig.

53). DO NOT tighten until all fasteners are in place.

(3) Lower vehicle and install upper exhaust mani-

fold fasteners (Fig. 53). Tighten all manifold bolts
starting at center and working outward to 25 N·m
(18 ft. lbs.).

CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.

(4) Install exhaust manifold heat shield (Fig. 53).

Tighten fasteners to 8 N·m (72 in. lbs.), then loosen
45 degrees.

(5) Connect exhaust pipe to manifold.
(6) Connect negative cable to battery.

CYLINDER HEAD COVER

REMOVAL

LEFT SIDE COVER

(1) Disconnect negative cable from battery.
(2) Remove the resonator assemble and air inlet

hose.

(3) Disconnect injector connectors and un-clip the

injector harness.

(4) Route injector harness in front of cylinder head

cover.

(5) Disconnect the left side breather tube and

remove the breather tube.

(6) Remove the cylinder head cover mounting

bolts.

(7) Remove cylinder head cover and gasket.

NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.

INSTALLATION

CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.

CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the cylin-
der head cover. Prolonged contact with other
objects may wear a hole in the engine cylinder head
cover.

(1) Clean cylinder head cover and both sealing sur-

faces. Inspect and replace gasket as necessary.

(2) Install cylinder head cover and hand start all

fasteners. Verify that all studs are in the correct loca-
tion shown in (Fig. 54).

(3) Tighten cylinder head cover bolts and double

ended studs to 12 N·m (105 in. lbs.).

(4) Install left side breather and connect breather

tube.

(5) Connect injector electrical connectors and injec-

tor harness retaining clips.

(6) Install the resonator and air inlet hose.
(7) Connect negative cable to battery.

REMOVAL

RIGHT SIDE COVER

(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly, resonator assem-

bly and air inlet hose.

(3) Drain cooling system, below the level of the

heater hoses. Refer to COOLING SYSTEM.

(4) Remove accessory drive belt.
(5) Remove air conditioning compressor retaining

bolts and move compressor to the left.

(6) Remove heater hoses.
(7) Disconnect injector and ignition coil connectors.
(8) Disconnect and remove positive crankcase ven-

tilation (PCV) hose.

(9) Remove oil fill tube.
(10) Un-clip injector and ignition coil harness and

move away from cylinder head cover.

(11) Remove right rear breather tube and filter

assembly.

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4.7L ENGINE

DN

REMOVAL AND INSTALLATION (Continued)