Dodge Durango (DN). Manual — part 425
ENGINE ASSEMBLY
REMOVAL
NOTE: This procedure applies to both the 4X2 and
4X4 vehicles, steps that apply to the 4X4 vehicle
only, are identified.
(1) Disconnect the battery negative and positive
cables.
(2) Remove the battery and the battery tray. Refer
to BATTERY.
(3) Raise vehicle on hoist.
(4) Remove exhaust crossover pipe from exhaust
manifolds. Refer to EXHAUST SYSTEM.
(5) 4X4 vehicles Disconnect axle vent tube from
left side engine mount.
(6) Remove the through bolt retaining nut and bolt
from both the left and right side engine mounts (Fig.
40) (Fig. 41).
(7) 4X4 vehicles Remove locknut from left and
right side engine mount brackets (Fig. 41).
(8) Disconnect two ground straps from the lower
left hand side and one ground strap from the lower
right hand side of the engine.
(9) Disconnect crankshaft position sensor. (Fig. 43)
NOTE: The following step applies to 4X4 vehicles
equipped with automatic transmission only.
(10) 4X4
vehicles
Remove
the
axle
isolator
bracket from the engine, transmission and the axle
(Fig. 42).
(11) Remove structural cover. Refer to Structural
Cover in this section for procedure.
(12) Remove starter. Refer to STARTING SYS-
TEM.
(13) Drain cooling system. Refer to COOLING
SYSTEM.
(14) Remove torque converter bolts (Automatic
Transmission Only). Refer to TRANSMISSION.
(15) Remove
transmission
to
engine
mounting
bolts.
(16) Disconnect the engine block heater power
cable from the block heater, if equipped.
(17) Lower vehicle.
(18) Remove throttle body resonator assembly and
air inlet hose.
(19) Disconnect throttle and speed control cables.
(20) Disconnect tube from both the left and right
side crankcase breathers (Fig. 44). Remove breathers
(21) Discharge A/C system. Refer to HEATING and
AIR CONDITIONING.
(22) Remove A/C compressor.
(23) Remove shroud, fan assemblies and accessory
drive belt. Refer to COOLING SYSTEM.
(24) Disconnect transmission oil cooler lines at the
radiator.
(25) Disconnect radiator upper and lower hoses.
Refer to COOLING SYSTEM.
(26) Remove radiator, A/C condenser and transmis-
sion oil cooler as an assembly. Refer to COOLING
SYSTEM.
(27) Remove generator.
(28) Disconnect the two heater hoses from the tim-
ing chain cover and heater core.
(29) Unclip and remove heater hoses and tubes
from the intake manifold (Fig. 45).
(30) Disconnect engine harness at the following
points :
• Intake air temperature (IAT) sensor (Fig. 46)
• Fuel Injectors
SEQUENCE
ITEM
TORQUE
1
BOLT
54 N·m
(Qty 4)
(40 ft. lbs.)
2
BOLT
54 N·m
(Qty 2)
(40 ft. lbs.)
3
BOLT
54 N·m
(Qty 2)
(40 ft. lbs.)
Fig. 40 Engine Mount Through Bolt and Nut
Removal / Installation—4X2 Vehicles
1 – LOCKNUT AND WASHER
2 – ENGINE MOUNT/INSULATOR
3 – THROUGH BOLT
4 – FRAME
DN
4.7L ENGINE
9 - 31
REMOVAL AND INSTALLATION (Continued)
• Throttle Position (TPS) Switch
• Idle Air Control (IAC) Motor
• Engine Oil Pressure Switch
• Engine Coolant Temperature (ECT) Sensor
• Manifold absolute pressure (MAP) Sensor
• Camshaft Position (CMP) Sensor
• Coil Over Plugs
(31) Disconnect the vacuum lines at the throttle
body and intake manifold.
(32) Release fuel rail pressure then disconnect the
fuel supply quick connect fitting at the fuel rail.
Refer toFUEL SYSTEM for procedure.
(33) Remove power steering pump and position out
of the way.
(34) Install Special Tools 8400 Lifting Studs, into
the cylinder heads.
(35) Install Engine Lifting Fixture Special Tool
8347 (Fig. 47) following these steps.
• Holding the lifting fixture at a slight angle, slide
the large bore in the front plate over the hex portion
of the lifting stud.
• Position the two remaining fixture arms onto
the two Special Tools 8400 Lifting Studs, in the cyl-
inder heads.
• Pull foward and upward on the lifting fixture so
that the lifting stud rest in the slotted area below the
large bore.
• Secure the lifting fixture to the three studs
using three 7/16 – 14 N/C locknuts.
• Make sure the lifting loop in the lifting fixture is
in the last hole (closest to the throttle body) to min-
imize the angle of engine during removal.
(36) Disconnect body ground strap at the right side
cowl (Fig. 48).
(37) Disconnect body ground strap at the left side
cowl (Fig. 49).
NOTE: It will be necessary to support the transmis-
sion in order to remove the engine.
(38) Position a suitable jack under the transmis-
sion.
(39) Remove engine from the vehicle.
INSTALLATION
(1) Position engine in the vehicle.
Position both the left and right side engine mount
brackets and install the through bolts and nuts.
Tighten nuts to 4X2 vehicles 95 N·m (70 ft. lbs.).
4X4 vehicles 102 N·m (75 ft. lbs.).
Fig. 41 Engine Mount Through Bolt and Nut
Removal / Installation—4X4 Vehicles
1 – ENGINE MOUNT BRACKET (2)
2 – THROUGH BOLT (2)
3 – LOCKNUT AND WASHER (2)
4 – ENGINE ISOLATOR TO ENGINE MOUNT BRACKET STUD (2)
5 – LOCKNUT (2)
Fig. 42 Axle Isolator Bracket Removal /
Installation—4X4 Vehicles With Automatic
Transmission
1 – TRANSMISSION
2 – AXLE ISOLATOR BRACKET
3 – FRONT AXLE 4X4 VEHICLES
4 – BOLTS
5 – ENGINE
9 - 32
4.7L ENGINE
DN
REMOVAL AND INSTALLATION (Continued)
(2) 4X4 vehicles Install locknuts onto the engine
mount brackets. Tighten locknuts to 41 N·m (30 ft.
lbs.).
(3) Remove jack from under the transmission.
(4) Remove Engine Lifting Fixture Special Tool
8347 (Fig. 47).
(5) Remove Special Tools 8400 Lifting Studs.
(6) Position generator wiring behind the oil dip-
stick tube, then install the oil dipstick tube upper
mounting bolt.
(7) Connect both left and right side body ground
straps.
(8) Install power steering pump.
(9) Connect fuel supply line quick connect fitting.
(10) Connect the vacuum lines at the throttle body
and intake manifold.
(11) Connect
engine
harness
at
the
following
points (Fig. 46) :
• Intake Air Temperature (IAT) Sensor
• Idle Air Control (IAC) Motor
• Fuel Injectors
• Throttle Position (TPS) Switch
• Engine Oil Pressure Switch
• Engine Coolant Temperature (ECT) Sensor
• Manifold Absolute Pressure (MAP) Sensor
• Camshaft Position (CMP) Sensor
• Coil Over Plugs
(12) Position and install heater hoses and tubes
onto intake manifold.
(13) Install the heater hoses onto the heater core
and the engine front cover.
(14) Install generator.
(15) Install A/C condenser, radiator and transmis-
sion oil cooler as an assembly.
(16) Connect radiator upper and lower hoses.
(17) Connect the transmission oil cooler lines to
the radiator.
(18) Install accessory drive belt, fan assembly and
shroud.
(19) Install A/C compressor. Tighten the A/C com-
pressor and generator M10 mounting bolts 40–68N·M
(30–50 ft. lbs.) and the M8 bolts 22–34 N·m (200–300
in. lbs.).
Fig. 43 Crankshaft Position Sensor
1 – CRANKSHAFT POSITION SENSOR
2 – CYLINDER HEAD COVER
3 – CAMSHAFT POSITION SENSOR
4 – RIGHT SIDE CYLINDER BLOCK
Fig. 44 Crankcase Breather Connection Points
1 – CRANKCASE BREATHERS
Fig. 45 Heater Hoses and Tubes Removal /
Installation
1 – HEATER HOSES AND TUBES
2 – ROUTING/RETAINING CLIPS
DN
4.7L ENGINE
9 - 33
REMOVAL AND INSTALLATION (Continued)
(20) Install both breathers. Connect tube to both
crankcase breathers (Fig. 44).
(21) Connect throttle and speed control cables.
(22) Install throttle body resonator assembly and
air inlet hose. Tighten clamps 4 N·m (35 in. lbs.).
(23) Raise vehicle.
(24) Install transmission to engine mounting bolts.
Tighten the bolts to 41 N·m (30 ft. lbs.).
(25) Install
torque
converter
bolts
(Automatic
Transmission Only).
(26) Connect crankshaft position sensor (Fig. 43).
(27)
4X4 vehicles Position and install the axle
isolator bracket onto the axle, transmission and
engine block. Tighten bolts to specification. Refer to
Specifications in this section.
(28) Install starter.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(29) Install structural cover. Refer to Structural
Cover in this section.
(30) Install exhaust crossover pipe.
(31) Install engine block heater power cable, If
equipped.
(32)
4X4 vehicles Connect axle vent tube to left
side engine mount.
(33) Lower vehicle.
(34) Check and fill engine oil.
(35) Recharge the A/C system.
(36) Refill the engine cooling system. Refer to
COOLING SYSTEM.
(37) Install the battery tray and battery.
(38) Connect the battery positive and negative
cables.
(39) Start the engine and check for leaks.
Fig. 46 Throttle Body Connection Points
1 – THROTTLE BODY
2 – TPS
3 – IAC MOTOR
4 – IAT SENSOR
5 – MOUNTING SCREWS
Fig. 47 Engine Lifting Fixture Attachment Locations
1 – ATTACHING LOCATION
2 – ADJUSTABLE HOOK
3 – SPECIAL TOOL 8347 ENGINE LIFT FIXTURE
4 – ATTACHING LOCATIONS
9 - 34
4.7L ENGINE
DN
REMOVAL AND INSTALLATION (Continued)
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