Dodge Durango (DN). Manual — part 455

(2) Check intake manifold bolt torque.
(3) Perform cylinder compression test. Refer to

Cylinder Compression Pressure Test in the Engine
Diagnosis area of this section.

(4) Clean or replace spark plugs as necessary and

adjust gap as specified in Electrical Group 8D.
Tighten to specifications.

(5) Test resistance of spark plug cables. Refer to

Electrical Group 8D, Spark Plug Cables.

(6) Inspect the primary wires. Test coil output volt-

age and primary resistance. Replace parts as neces-
sary. Refer to Electrical Group 8D, for specifications.

(7) Test fuel pump for pressure. Refer to Group 14,

Fuel System Specifications.

(8) The air filter elements should be replaced as

specified in Lubrication and Maintenance, Group 0.

(9) Inspect crankcase ventilation system as out

lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.

(10) Road test vehicle as a final test.

ENGINE OIL

WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.

ENGINE OIL SPECIFICATION

CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.

API SERVICE GRADE CERTIFIED

In gasoline engines, use an engine oil that is API

Service Grade Certified (Fig. 12). Standard engine oil
identification notations have been adopted to aid in
the proper selection of engine oil. The identifying
notations are located on the label of engine oil plastic
bottles and the top of engine oil cans. MOPAR only
provides engine oil that conforms to this certification.

SAE VISCOSITY

An SAE viscosity grade is used to specify the vis-

cosity of engine oil. SAE 10W-30 specifies a multiple
viscosity engine oil. These are specified with a dual

SAE viscosity grade which indicates the cold-to-hot
temperature viscosity range. When choosing an
engine oil, consider the range of temperatures the
vehicle will be operated in before the next oil change.
Select an engine oil that is best suited to your area’s
particular ambient temperature range and variation
(Fig. 13).

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for

gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.

OIL LEVEL INDICATOR (DIPSTICK)

The engine oil level indicator is located at the right

front of the engine, left of the generator on 5.9L
engines (Fig. 14).

CRANKCASE OIL LEVEL INSPECTION

CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.

To ensure proper lubrication of an engine, the

engine oil must be maintained at an acceptable level.
The acceptable levels are indicated between the ADD
and SAFE marks on the engine oil dipstick.

(1) Position vehicle on level surface.

Fig. 12 Engine Oil Container Standard Notations

Fig. 13 Temperature/Engine Oil Viscosity

Recommendation

9 - 150

5.9L ENGINE

DN

SERVICE PROCEDURES (Continued)

(2) With engine OFF, allow approximately ten min-

utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.

(3) Wipe dipstick clean.
(4) Install dipstick and verify it is seated in the

tube.

(5) Remove dipstick, with handle held above the

tip, take oil level reading.

(6) Add oil only if level is below the ADD mark on

dipstick.

ENGINE OIL CHANGE

Change engine oil at mileage and time intervals

described in the Maintenance Schedule. This infor-
mation can be found in your owner’s manual.

TO CHANGE ENGINE OIL

Run engine until achieving normal operating tem-

perature.

(1) Position the vehicle on a level surface and turn

engine off.

(2) Hoist and support vehicle on safety stands.

Refer to Hoisting and Jacking Recommendations.

(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase

drain.

(5) Remove drain plug from crankcase and allow

oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.

(6) Install drain plug in crankcase.

(7) Lower vehicle and fill crankcase with specified

type and amount of engine oil described in this sec-
tion.

(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.

ENGINE OIL FILTER CHANGE

FILTER SPECIFICATION

All engines are equipped with a high quality full-

flow, disposable type oil filter. DaimlerChrysler Cor-
poration recommends a Mopar or equivalent oil filter
be used.

OIL FILTER REMOVAL

(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise to remove

it from the cylinder block oil filter boss (Fig. 15).

(4) When filter separates from adapter nipple, tip

gasket end upward to minimize oil spill. Remove fil-
ter from vehicle.

(5) With a wiping cloth, clean the gasket sealing

surface (Fig. 16) of oil and grime.

OIL FILTER INSTALLATION

(1) Lightly lubricate oil filter gasket with engine

oil or chassis grease.

(2) Thread filter onto adapter nipple. When gasket

makes contact with sealing surface, (Fig. 16) hand
tighten filter one full turn, do not over tighten.

(3) Add oil, verify crankcase oil level and start

engine. Inspect for oil leaks.

REPAIR DAMAGED OR WORN THREADS

CAUTION: Be sure that the tapped holes maintain
the original center line.

Fig. 14 Engine Oil Dipstick Location—5.9L Engines

1 – CYLINDER HEAD COVER
2 – ENGINE OIL FILL-HOLE CAP
3 – DIPSTICK
4 – ENGINE OIL FILTER
5 – FILTER BOSS

Fig. 15 Oil Filter Removal—Typical

1 – ENGINE OIL FILTER
2 – OIL FILTER WRENCH

DN

5.9L ENGINE

9 - 151

SERVICE PROCEDURES (Continued)

Damaged or worn threads can be repaired. Essen-

tially, this repair consists of:

• Drilling out worn or damaged threads.

• Tapping the hole with a special Heli-Coil Tap, or

equivalent.

• Installing an insert into the tapped hole to bring

the hole back to its original thread size.

CYLINDER BORE—HONING

Before honing, stuff plenty of clean shop towels

under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.

(1) Used carefully, the Cylinder Bore Sizing Hone

C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.

CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.

(2) Deglazing of the cylinder walls may be done if

the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.

CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.

(3) Honing should be done by moving the hone up

and down fast enough to get a crosshatch pattern.

The hone marks should INTERSECT at 50° to 60°
for proper seating of rings (Fig. 17).

(4) A controlled hone motor speed between 200 and

300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50° to 60°
angle. Faster up and down strokes increase the cross-
hatch angle.

(5) After honing, it is necessary that the block be

cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.

HYDROSTATIC LOCK

When an engine is suspected of hydrostatic lock

(regardless of what caused the problem), follow the
steps below.

(1) Perform the Fuel Pressure Release Procedure

(refer to Group 14, Fuel System).

(2) Disconnect the battery negative cable.
(3) Inspect

air

cleaner,

induction

system

and

intake manifold to ensure system is dry and clear of
foreign material.

(4) Place a shop towel around the spark plugs to

catch any fluid that may possibly be under pressure
in the cylinder head. Remove the plugs from the
engine.

CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.

(5) With all spark plugs removed, rotate the crank-

shaft using a breaker bar and socket.

Fig. 16 Oil Filter Sealing Surface—Typical

1 – SEALING SURFACE
2 – RUBBER GASKET
3 – OIL FILTER

Fig. 17 Cylinder Bore Crosshatch Pattern

1 – CROSSHATCH PATTERN
2 – INTERSECT ANGLE

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5.9L ENGINE

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SERVICE PROCEDURES (Continued)

(6) Identify the fluid in the cylinders (i.e. coolant,

fuel, oil, etc.).

(7) Make sure all fluid has been removed from the

cylinders.

(8) Repair engine or components as necessary to

prevent this problem from occurring again.

(9) Squirt engine oil into the cylinders to lubricate

the walls. This will prevent damage on restart.

(10) Install new spark plugs.
(11) Drain engine oil. Remove and discard the oil

filter.

(12) Install the drain plug. Tighten the plug to 34

N·m (25 ft. lbs.) torque.

(13) Install a new oil filter.
(14) Fill

engine

crankcase

with

the

specified

amount and grade of oil.

(15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.

VALVE TIMING

(1) Turn crankshaft until the No.6 exhaust valve is

closing and No.6 intake valve is opening.

(2) Insert a 6.350 mm (1/4 inch) spacer between

rocker arm pad and stem tip of No.1 intake valve.
Allow spring load to bleed tappet down giving in
effect a solid tappet.

(3) Install a dial indicator so plunger contacts

valve spring retainer as nearly perpendicular as pos-
sible. Zero the indicator.

(4) Rotate the crankshaft clockwise (normal run-

ning direction) until the valve has lifted 0.863 mm
(0.034 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
top dead center. Remove spacer.

CAUTION: DO NOT turn crankshaft any further
clockwise as valve spring might bottom and result
in serious damage.

If reading is not within specified limits:
• Check sprocket index marks.

• Inspect timing chain for wear.

• Check accuracy of DC mark on timing indicator.

VALVE SERVICE

VALVE CLEANING

Clean valves thoroughly. Discard burned, warped

and cracked valves.

Remove carbon and varnish deposits from inside of

valve guides with a reliable guide cleaner.

VALVE INSPECTION

Measure valve stems for wear. If wear exceeds

0.051 mm (0.002 inch), replace the valve.

VALVE GUIDES

Measure valve stem guide clearance as follows:
(1) Install Valve Guide Sleeve Tool C-3973 over

valve stem and install valve (Fig. 18). The special
sleeve places the valve at the correct height for
checking with a dial indicator.

(2) Attach Dial Indicator Tool C-3339 to cylinder

head and set it at right angle of valve stem being
measured (Fig. 19).

(3) Move valve to and from the indicator. The total

dial indicator reading should not exceed 0.432 mm
(0.017 inch). Ream the guides for valves with over-
size stems if dial indicator reading is excessive or if
the stems are scuffed or scored.

Service valves with oversize stems are available as

shown below.

Slowly turn reamer by hand and clean guide thor-

oughly before installing new valve. Ream the valve
guides from standard to 0.381 mm (0.015 inch).

Fig. 18 Positioning Valve with Tool C-3973

1 – VALVE
2 – SPACER TOOL

Fig. 19 Measuring Valve Guide Wear

1 – VALVE
2 – SPECIAL TOOL C-3339

DN

5.9L ENGINE

9 - 153

SERVICE PROCEDURES (Continued)