Dodge Durango (DN). Manual — part 461

CRANKSHAFT MAIN BEARINGS

REMOVAL

(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-

ing cap.

(3) Identify bearing caps before removal. Remove

bearing caps one at a time.

(4) Remove upper half of bearing by inserting

Crankshaft

Main

Bearing

Remover/Installer

Tool

C-3059 into the oil hole of crankshaft (Fig. 67).

(5) Slowly rotate crankshaft clockwise, forcing out

upper half of bearing shell.

INSTALLATION

Only one main bearing should be selectively fitted

while all other main bearing caps are properly tight-
ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal-
lation.

When installing a new upper bearing shell, slightly

chamfer the sharp edges from the plain side.

(1) Start bearing in place, and insert Crankshaft

Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 67).

(2) Slowly rotate crankshaft counterclockwise slid-

ing the bearing into position. Remove Tool C-3059.

(3) Install the bearing caps. Clean and oil the bolts.

Tighten the capbolts to 115 N·m (85 ft. lbs.) torque.

(4) Install the oil pump.
(5) Install the oil pan.
(6) Start engine check for leaks.

OIL PAN

REMOVAL

2WD

(1) Disconnect the negative cable from the battery.
(2) Remove air cleaner assembly.
(3) Remove engine oil dipstick.

(4) Disconnect distributor cap and position away

from cowl.

(5) Remove the fan shroud. Refer to COOLING

SYSTEM.

(6) Disconnect throttle valve cable from throttle

body and mounting bracket (Fig. 67A).

(7) Raise vehicle.
(8) Drain engine oil.
(9) Remove exhaust pipe from exhaust manifolds.
(10) Remove engine mount insulator through bolts.
(11) Raise engine by way of oil pan using a block of

wood between the jack and oil pan.

(12) When engine is high enough, place mount

through bolts in the engine mount attaching points on
the frame brackets.

(13) Lower engine so bottom of engine mounts rest

on the replacement bolts placed in the engine mount
frame brackets.

(14) Remove transmission to engine braces.
(15) Remove starter. Refer to STARTING SYS-

TEMS.

(16) Remove transmission torque converter inspec-

tion cover.

(17) Disconnect rear support cushion from cross-

member.

(18) Raise rear of transmission away from cross-

member.

(19) Remove oil pan and one-piece gasket.

4WD

(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove front driving axle. Refer to DIFFEREN-

TIAL and DRIVELINE.

(6) Remove both engine mount support brackets.
(7) Remove transmission torque converter inspec-

tion cover.

(8) Remove oil pan and one-piece gasket.

Fig. 67 Upper Main Bearing Removal and

Installation with Tool C-3059

1 – SPECIAL TOOL C-3059
2 – BEARING
3 – SPECIAL TOOL C-3059
4 – BEARING

Fig. 67A Throttle Valve Cable Removal/Installation

1 – TRANSMISSION THROTTLE VALVE CABLE BRACKET
2 – AIR INLET DUCT
3 – TRANSMISSION THROTTLE VALVE CABLE

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5.9L ENGINE

DN

REMOVAL AND INSTALLATION (Continued)

2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99

December, 1999

INSTALLATION

2WD

(1) Fabricate 4 alignment dowels from 5/16 x 1 1/2

inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier instal-
lation and removal with a screwdriver (Fig. 68).

(2) Install the dowels in the cylinder block (Fig. 69).

(3) Apply small amount of Mopar Silicone Rubber

Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.

(4) Slide the one-piece gasket over the dowels and

onto the block.

(5) Position the oil pan over the dowels and onto

the gasket.

(6) Install the oil pan bolts. Tighten the bolts to 24

N·m (215 in. lbs.) torque.

(7) Remove the dowels. Install the remaining oil

pan bolts. Tighten these bolts to 24 N·m (215 in. lbs.)
torque.

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

N·m (25 ft. lbs.) torque.

(9) Lower transmission onto crossmember.
(10) Install rear support cushion mounting bolts.

Tighten bolts 28 N·m (250 in. lbs.).

(11) Raise engine by way of oil pan with a wood

block placed between jack and oil pan.

(12) Remove through bolts from frame brackets

and lower engine. Install mount insulator through
bolts and tighten to 95 N·m (70 ft. lbs.).

(13) Install starter.
(14) Install transmission torque converter inspec-

tion cover.

(15) Install engine to transmission braces.
(16) Install exhaust pipe.
(17) Lower vehicle.
(18) Position throttle valve cable into bracket, then

attach to throttle body (Fig. 67A).

(19) Connect the distributor cap.
(20) Install dipstick.
(21) Install fan shroud.
(22) Install air cleaner assembly.
(23) Connect the negative cable to the battery.
(24) Fill crankcase with oil to proper level.

4WD

(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16

inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier instal-
lation and removal with a screwdriver (Fig. 68).

(2) Install the dowels in the cylinder block (Fig. 69).
(3) Apply small amount of Mopar Silicone Rubber

Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.

(4) Slide the one-piece gasket over the dowels and

onto the block.

(5) Position the oil pan over the dowels and onto

the gasket.

(6) Install the oil pan bolts. Tighten the bolts to 24

N·m (215 in. lbs.) torque.

(7) Remove the dowels. Install the remaining oil pan

bolts. Tighten these bolts to 24 N·m (215 in. lbs.) torque.

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

N·m (25 ft. lbs.) torque.

(9) Install transmission inspection cover.
(10) Install engine mount support brackets and

insulators.

(11) Install front drive axle. Refer to DIFFEREN-

TIAL and DRIVELINE.

(12) Lower vehicle
(13) Connect the distributor cap.
(14) Install dipstick.
(15) Connect the negative cable to the battery.
(16) Fill crankcase with oil to proper level.

PISTON AND CONNECTING ROD ASSEMBLY

REMOVAL

(1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.
(4) Remove top ridge of cylinder bores with a reli-

able ridge reamer before removing pistons from cylin-
der block. Be sure to keep tops of pistons covered
during this operation.

(5) Be sure the connecting rod and connecting rod

cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.

(6) Pistons and connecting rods must be removed

from top of cylinder block. When removing piston and
connecting rod assemblies, rotate crankshaft to center
the connecting rod in the cylinder bore and at BDC.
Be careful not to nick crankshaft journals.

(7) After removal, install bearing cap on the mating rod.

Fig. 68 Fabrication of Alignment Dowels

1 – 1 1/2” x 5/16” BOLT
2 – DOWEL
3 – SLOT

Fig. 69 Position of Dowels in Cylinder Block

1 – DOWEL
2 – DOWEL
3 – DOWEL
4 – DOWEL

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5.9L ENGINE

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REMOVAL AND INSTALLATION (Continued)

2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99

December, 1999

INSTALLATION

(1) Be sure that compression ring gaps are stag-

gered so that neither is in-line with oil ring rail gap.

(2) Before installing the ring compressor, make

sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 70).

(3) Immerse the piston head and rings in clean

engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.

(4) Install connecting rod bolt protectors on rod

bolts, the long protector should be installed on the
numbered side of the connecting rod.

(5) Rotate crankshaft so that the connecting rod

journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.

(6) Tap the piston down in cylinder bore, using a

hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.

(7) The notch or groove on top of piston must be

pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.

(8) Install rod caps. Be sure connecting rod, con-

necting rod cap and cylinder bore number are the
same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 N·m (45 ft. lbs.) torque.

(9) Install the oil pan.
(10) Install the cylinder head.
(11) Install the engine into the vehicle.

CRANKSHAFT

A crankshaft which has undersize journals will be

stamped with 1/4 inch letters on the milled flat on
the No.3 crankshaft counterweight (Fig. 71).

FOR EXAMPLE: R2 stamped on the No.3 crank-

shaft counterweight indicates that the No.2 rod jour-
nal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in)
undersize. R3 M2 indicates that the No.3 rod journal
and the No.2 main journal are 0.025 mm (0.001 in)
undersize.

When a crankshaft is replaced, all main and con-

necting rod bearings should be replaced with new
bearings. Therefore, selective fitting of the bearings
is not required when a crankshaft and bearings are
replaced.

REMOVAL

(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-

ing cap.

(3) Remove the vibration damper.
(4) Remove the timing chain cover.
(5) Identify bearing caps before removal. Remove

bearing caps and bearings one at a time.

(6) Lift the crankshaft out of the block.

Fig. 70 Proper Ring Installation

1 – OIL RING SPACER GAP
2 – SECOND COMPRESSION RING GAP OIL RING RAIL GAP

(TOP)

3 – OIL RING RAIL GAP (BOTTOM)
4 – TOP COMPRESSION RING GAP

Fig. 71 Location of Crankshaft Identification

1 – 1/4” LETTERS
2 – (ROD)
3 – (MAIN)

CRANKSHAFT IDENTIFICATION MARK

LOCATION CHART

UNDERSIZE JOURNAL

IDENTIFICATION

STAMP

0.025 mm (0.001 in.)

(ROD)

R1-R2-R3 or R4

0.025 mm (0.001 in.)

(MAIN)

M1-M2-M3-M4 or M5

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5.9L ENGINE

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REMOVAL AND INSTALLATION (Continued)

(7) Remove and discard the crankshaft rear oil

seals.

(8) Remove and discard the front crankshaft oil

seal.

INSPECTION OF JOURNALS

The crankshaft connecting rod and main journals

should be checked for excessive wear, taper and scor-
ing. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 inch).

Journal grinding should not exceed 0.305 mm

(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO
NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and
clean out all oil passages.

CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction as the engine rotates.

CLEANING

Clean Loctite 518 residue and sealant from the cyl-

inder block and rear cap mating surface. Do this
before applying the Loctite drop and the installation
of rear cap.

INSTALLATION

(1) Lightly oil the new upper seal lips with engine

oil.

(2) Install the new upper rear bearing oil seal with

the white paint facing towards the rear of the engine.

(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine

oil.

(5) Install the new lower rear bearing oil seal into

the bearing cap with the white paint facing towards
the rear of the engine.

(6) Apply 5 mm (0.20 in) drop of Loctite 518, or

equivalent, on each side of the rear main bearing cap
(Fig. 72). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cap to cylinder block immediately after sealant appli-
cation.

(7) To align the bearing cap, use cap slot, align-

ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.

(8) Clean and oil all cap bolts. Install all main

bearing caps. Install all cap bolts and alternately
tighten to 115 N·m (85 ft. lbs.) torque.

(9) Install oil pump.
Apply Mopar

t Silicone Rubber Adhesive Sealant,

or equivalent, at bearing cap to block joint to provide
cap to block and oil pan sealing (Fig. 73). Apply
enough sealant until a small amount is squeezed out.

Withdraw nozzle and wipe excess sealant off the oil
pan seal groove.

(10) Install new front crankshaft oil seal.
(11) Immediately install the oil pan.

OIL PUMP

REMOVAL

(1) Remove the oil pan.
(2) Remove the oil pump from rear main bearing

cap.

INSTALLATION

(1) Install oil pump. During installation slowly

rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.

Fig. 72 Sealant Application to Bearing Cap

1 – .25 DROP OF LOCTITE 515 ON BOTH SIDES OF REAR

MAIN CAP

Fig. 73 Apply Sealant to Bearing Cap to Block Joint

1 – MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE

TIP

2 – SEALANT APPLIED
3 – CYLINDER BLOCK
4 – REAR MAIN BEARING CAP

DN

5.9L ENGINE

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REMOVAL AND INSTALLATION (Continued)