Dodge Durango (DN). Manual — part 449

Place a straightedge across the face of the pump,

between bolt holes. If a feeler gauge of 0.102 mm
(0.004 inch) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig.
89).

Inspect oil pressure relief valve plunger for scoring

and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.

The relief valve spring has a free length of approx-

imately 49.5 mm (1.95 inches). The spring should
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring that fails
to meet these specifications (Fig. 90).

Fig. 85 Measuring Outer Rotor Thickness

Fig. 86 Measuring Inner Rotor Thickness

Fig. 87 Measuring Outer Rotor Clearance in

Housing

1 – PUMP BODY
2 – OUTER ROTOR
3 – FEELER GAUGE

Fig. 88 Measuring Clearance Between Rotors

1 – OUTER ROTOR
2 – FEELER GAUGE
3 – INNER ROTOR

Fig. 89 Measuring Clearance Over Rotors

1 – STRAIGHT EDGE
2 – FEELER GAUGE

9 - 126

5.2L ENGINE

DN

CLEANING AND INSPECTION (Continued)

If oil pressure was low and pump is within specifi-

cations, inspect for worn engine bearings or other
reasons for oil pressure loss.

CYLINDER BLOCK

CLEANING

Clean cylinder block thoroughly and check all core

hole plugs for evidence of leaking.

INSPECTION

Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-

round and taper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:

• The cylinder bores show more than 0.127 mm

(0.005 inch) out-of-round.

• The cylinder bores show a taper of more than

0.254 mm (0.010 inch).

• The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-

dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.

Refer to Standard Service Procedures in the begin-

ning of this Group for the proper honing of cylinder
bores.

INTAKE MANIFOLD

CLEANING

Clean manifold in solvent and blow dry with com-

pressed air.

Clean cylinder block front and rear gasket surfaces

using a suitable solvent.

The plenum pan rail must be clean and dry (free of

all foreign material).

INSPECTION

Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness

with a straightedge.

EXHAUST MANIFOLD

CLEANING

Clean mating surfaces on cylinder head and mani-

fold, wash with solvent and blow dry with com-
pressed air.

INSPECTION

Inspect manifold for cracks, Inspect mating sur-

faces of manifold for flatness with a straight edge.
Seal surfaces must be flat within 0.1 mm (0.004 inch)
overall.

Fig. 90 Proper Installation of Retainer Cap

1 – RETAINER CAP
2 – CHAMFER
3 – COTTER KEY

DN

5.2L ENGINE

9 - 127

CLEANING AND INSPECTION (Continued)

SPECIFICATIONS

5.2L ENGINE SPECIFICATIONS

ENGINE SPECIFICATIONS

DESCRIPTION

SPECIFICATION

GENERAL SPECIFICATIONS

Engine Type

90° V-8 OHV

Bore and Stroke

99.3 x 84.0 mm

(3.91 x 3.31 in.)

Displacement

5.2L

(318 c.i.)

Compression Ratio

9.1:1

Firing Order

1–8–4–3–6–5–7–2

Lubrication

Pressure Feed—

Full Flow Filtration

Cooling System

Liquid Cooled—

Forced Circulation

Cylinder Block

Cast Iron

Crankshaft

Nodular Iron

Cylinder Head

Cast Iron

Combustion Chambers

Wedge-High Swirl

Valve shrouding

Camshaft

Nodular Cast Iron

Pistons

Aluminum Alloy w/strut

Connecting Rods

Forged Steel

Cylinder Compression

689.5 kPa

Pressure (Min.)

(100 psi)

CAMSHAFT

Bearing Diameter

No. 1

50.800 – 50.825 mm

(2.000 – 2.001 in.)

No. 2

50.394 – 50.419 mm

(1.984 – 1.985 in.)

No. 3

50.013 – 50.038 mm

(1.969 – 1.970 in.)

No. 4

49.606 – 49.632 mm

(1.953 – 1.954 in.)

DESCRIPTION

SPECIFICATION

No. 5

39.688 – 39.713 mm

(1.5625 – 1.5635 in.)

Bearing Journal Diameter

No. 1

50.749 – 50.775 mm

(1.998 – 1.999 in.)

No. 2

50.343 – 50.368 mm

(1.982 – 1.983 in.)

No. 3

49.962 – 49.987 mm

(1.967 – 1.968 in.)

No. 4

49.555 – 49.581 mm

(1.951 – 1.952 in.)

No. 5

39.637 – 39.662 mm

(1.5605 – 1.5615 in.)

Bearing to Journal
Clearance

Standard

0.0254 – 0.0762 mm

(0.001 – 0.003 in.)

Service Limit

0.127 mm

(0.005 in.)

End Play

0.051 – 0.254 mm

(0.002 – 0.010 in.)

CONNECTING RODS

Piston Pin bore Diameter

24.966 – 24.978 mm

(0.9829 – 0.9834 in.)

Side Clearance

0.152 – 0.356 mm

(0.006 – 0.014 in.)

CRANKSHAFT

Rod Journal

Diameter

53.950 – 53.975 mm

(2.124 – 2.125 in.)

Out of Round (Max.)

0.0254 mm

(0.001 in.)

Taper (Max.)

0.0254 mm

(0.001 in.)

Bearing Clearance

0.013 – 0.056 mm

(0.0005 – 0.0022 in.)

Service Limit

0.0762 mm

(0.003 in.)

9 - 128

5.2L ENGINE

DN

DESCRIPTION

SPECIFICATION

Main Bearing Journal

Diameter

63.487 – 63.513 mm

(2.4995 – 2.5005 in.)

Out of Round (Max.)

0.127 mm

(0.001 in.)

Taper (Max.)

0.0254 mm

(0.001 in.)

Bearing Clearance

(#1 Journal)

0.013 – 0.038 mm

(0.0005 – 0.0015 in.)

(#2-5 Journals)

0.013 – 0.051 mm

(0.0005 – 0.002 in.)

Service Limit

(#1 Journal)

0.0381 mm

(0.0015 in.)

(#2-5 Journals)

0.064 mm

(0.0025 in.)

End Play

0.051 – 0.178 mm

(0.002 – 0.007 in.)

Service Limit

0.254 mm

(0.010 in.)

CYLINDER BLOCK

Cylinder Bore

Diameter

99.308 – 99.371 mm

(3.9098 – 3.9122 in.)

Out of Round (Max.)

0.025 mm

(0.001 in.)

Taper (Max.)

0.025 mm

(0.001 in.)

Oversize Limit

1.016 mm

(0.040 in.)

Lifter Bore Diameter

22.99 – 23.01 mm

(0.9051 – 0.9059 in.)

Distributor Drive Bushing

(Press Fit)

Bushing to Bore

Interference

0.0127 – 0.3556 mm

(0.0005 – 0.0140 in.)

Shaft to Bushing

Clearance

0.0178 – 0.0686 mm

(0.0007 – 0.0027 in.)

DESCRIPTION

SPECIFICATION

CYLINDER HEAD

Valve Seat

Angle

44.25° – 44.75°

Runout (Max.)

0.0762 mm

(0.003 in.)

Width (Finish)

Intake

1.016 – 1.524 mm

(0.040 – 0.060 in.)

Exhaust

1.524 – 2.032 mm

(0.060 – 0.080 in.)

VALVES

Face Angle

43.25° – 43.75°

Head Diameter

Intake

48.666 mm

(1.916 in.)

Exhaust

41.250 mm

(1.624 in.)

Length (Overall)

Intake

124.28 – 125.92 mm

(4.893 – 4.918 in.)

Exhaust

124.64 – 125.27 mm

(4.907 – 4.932 in.)

Lift (@ zero lash)

10.973 mm

(0.432 in.)

Stem Diameter

7.899 – 7.925 mm

(0.311 – 0.312 in.)

Guide Bore

7.950 – 7.976 mm

(0.313 – 0.314 in.)

Stem to Guide Clearance

0.0254 – 0.0762 mm

(0.001 – 0.003 in.)

Service Limit (rocking
method)

0.4318 mm

(0.017 in.)

DN

5.2L ENGINE

9 - 129

SPECIFICATIONS (Continued)