Index Dodge Dodge Durango (HB) - service repair manual 2005 year

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Dodge Durango (HB). Manual - part 1080

ENGINE - 5.7L SERVICE INFORMATION

TABLE OF CONTENTS

page

page

ENGINE - 5.7L SERVICE INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . 1321

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - INTRODUCTION . . . . . . . . . . 1321

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - PERFORMANCE . . . . . . . . . 1322

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - MECHANICAL . . . . . . . . . . . 1323

DIAGNOSIS AND TESTING - CYLINDER

COMPRESSION PRESSURE . . . . . . . . . . . 1324

DIAGNOSIS AND TESTING - CYLINDER

COMBUSTION PRESSURE LEAKAGE . . . . 1324

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - LUBRICATION . . . . . . . . . . . 1325

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - MECHANICAL . . . . . . . . . . . 1326

STANDARD PROCEDURE

STANDARD PROCEDURE - REPAIR

DAMAGED OR WORN THREADS . . . . . . . 1328

STANDARD PROCEDURE - HYDROSTATIC

LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1328

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1329

. . . . . . . . . . . . . . . . . . . . . . . 1333

. . . . . . . . . . . . . . . . . . . . . . . 1337

. . . . . . . . . . . . . . . . . . . . . . . . . . 1343

. . . . . . . . . . . . . . . . . . . . . . . 1345

AIR INTAKE SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1348

. . . . . . . . . . . . . . . . . . . . . . . 1349

CYLINDER HEAD

OPERATION—CYLINDER HEAD

. . . . . . . . . . 1350

DIAGNOSIS AND TESTING - CYLINDER HEAD

. . . . . . . . . . . . . . . . . . . 1350

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1351

. . . . . . . . . . . . . . . . . . . . . . . . . . 1354

. . . . . . . . . . . . . . . . . . . . . . . . . 1354

. . . . . . . . . . . . . . . . . . . . . . . 1355

COVER-CYLINDER HEAD

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1360

. . . . . . . . . . . . . . . . . . . . . . . 1363

VALVES & SEATS - INTAKE/EXHAUST

DESCRIPTION - VALVE GUIDES

. . . . . . . . 1365

. . . . . . . . . . . . . . . . . . . . . . 1365

STANDARD PROCEDURE - REFACING

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1366

. . . . . . . . . . . . . . . . . . . . . . . 1366

ROCKER ARM

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1367

. . . . . . . . . . . . . . . . . . . . . . . 1368

SEALS-VALVE GUIDE

. . . . . . . . . . . . . . . . . . . . . . . 1370

SPRINGS-VALVE

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1371

. . . . . . . . . . . . . . . . . . . . . . . 1377

ENGINE BLOCK

. . . . . . . . . . . . . . . . . . . . . . . . . . 1381

. . . . . . . . . . . . . . . . . . . . . . . . . 1382

CAMSHAFT

REMOVAL - CAMSHAFT CORE

HOLE PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1382

REMOVAL - CAMSHAFT

. . . . . . . . . . . . . . 1383

. . . . . . . . . . . . . . . . . . . . . . . . . 1387

INSTALLATION - CAMSHAFT CORE HOLE

PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1388

INSTALLATION - CAMSHAFT

. . . . . . . . . . . 1388

CRANKSHAFT

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1395

. . . . . . . . . . . . . . . . . . . . . . . 1399

BEARINGS-CRANKSHAFT MAIN

STANDARD PROCEDURE - CRANKSHAFT

MAIN BEARING - FITTING

. . . . . . . . . . . . . 1404

. . . . . . . . . . . . . . . . . . . . . . . . . 1404

SEAL-CRANKSHAFT OIL-FRONT

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1405

. . . . . . . . . . . . . . . . . . . . . . . 1406

SEAL-CRANKSHAFT OIL-REAR

DIAGNOSIS AND TESTING - REAR SEAL

. . . . . . . . . . . . . . . . . . . . . . . 1406

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1407

. . . . . . . . . . . . . . . . . . . . . . . 1408

RETAINER-CRANK REAR OIL - SEAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1408

. . . . . . . . . . . . . . . . . . . . . . . 1409

FLEX PLATE

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1410

. . . . . . . . . . . . . . . . . . . . . . . 1410

TAPPETS-HYDRAULIC ROLLER

DIAGNOSIS AND TESTING - HYDRAULIC

. . . . . . . . . . . . . . . . . . . . . . . . . . 1411

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1411

. . . . . . . . . . . . . . . . . . . . . . . 1413

PISTON & CONNECTING ROD

. . . . . . . . . . . . . . . . . . . . . . . 1413

STANDARD PROCEDURE - PISTON

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1414

HB

ENGINE - 5.7L SERVICE INFORMATION

9 - 1319

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1414

. . . . . . . . . . . . . . . . . . . . . . . . . . 1415

. . . . . . . . . . . . . . . . . . . . . . . . . 1416

. . . . . . . . . . . . . . . . . . . . . . . 1416

RINGS-PISTON

STANDARD PROCEDURE - PISTON RING

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1417

DAMPER-CRANKSHAFT

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1420

. . . . . . . . . . . . . . . . . . . . . . . 1421

COVER-STRUCTURAL

. . . . . . . . . . . . . . . . . . . . . . . 1422

. . . . . . . . . . . . . . . . . . . . . . . . . 1422

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1422

. . . . . . . . . . . . . . . . . . . . . . . 1422

ENGINE MOUNTING-FRONT

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1423

. . . . . . . . . . . . . . . . . . . . . . . 1423

MOUNTING-ENGINE REAR

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1424

. . . . . . . . . . . . . . . . . . . . . . . 1424

LUBRICATION

. . . . . . . . . . . . . . . . . . . . . . . 1425

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - CHECKING

ENGINE OIL PRESSURE . . . . . . . . . . . . . . 1425

DIAGNOSIS AND TESTING - ENGINE OIL

LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1426

OIL

STANDARD PROCEDURE - ENGINE OIL

. . . . . . . . . . . . . . . . . . . . . . . . . . 1427

FILTER-ENGINE OIL

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1427

. . . . . . . . . . . . . . . . . . . . . . . 1428

PAN-ENGINE OIL

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1428

. . . . . . . . . . . . . . . . . . . . . . . 1431

PUMP-ENGINE OIL

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1434

. . . . . . . . . . . . . . . . . . . . . . . . . . 1434

. . . . . . . . . . . . . . . . . . . . . . . . . 1435

. . . . . . . . . . . . . . . . . . . . . . . 1436

INTAKE MANIFOLD

. . . . . . . . . . . . . . . . . . . . . . . 1437

DIAGNOSIS AND TESTING - INTAKE

MANIFOLD LEAKAGE

. . . . . . . . . . . . . . . . 1437

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1437

. . . . . . . . . . . . . . . . . . . . . . . . . . 1437

. . . . . . . . . . . . . . . . . . . . . . . . . 1437

. . . . . . . . . . . . . . . . . . . . . . . 1438

MANIFOLD - EXHAUST

. . . . . . . . . . . . . . . . . . . . . . . 1438

. . . . . . . . . . . . . . . . . . . . . . . . . 1438

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1438

. . . . . . . . . . . . . . . . . . . . . . . . . . 1438

. . . . . . . . . . . . . . . . . . . . . . . . . 1439

. . . . . . . . . . . . . . . . . . . . . . . 1439

COVER-TIMING

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1440

. . . . . . . . . . . . . . . . . . . . . . . 1442

TIMING CHAIN & SPROCKETS

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1443

. . . . . . . . . . . . . . . . . . . . . . . 1446

TENSIONER - TIMING CHAIN

. . . . . . . . . . . . . . . . . . . . . . . 1449

. . . . . . . . . . . . . . . . . . . . . . . . . 1449

9 - 1320

ENGINE - 5.7L SERVICE INFORMATION

HB

ENGINE - 5.7L SERVICE INFORMATION

DESCRIPTION

The 5.7L engine (345 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum
heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with
a hemispherical style combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2.

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION

Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine main-
tenance.

HB

ENGINE - 5.7L SERVICE INFORMATION

9 - 1321

These malfunctions may be classified as either performance (e.g., engine idles rough and stalls) or mechanical
(e.g., a strange noise).

(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING) - PERFORMANCE and (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)—MECHANICAL for possible causes and corrections of malfunctions. (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY - DIAGNOSIS AND TESTING) and (Refer to 14 - FUEL SYSTEM/FUEL INJECTION - DIAGNO-
SIS AND TESTING) for the fuel system diagnosis.

Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be iso-
lated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the
following diagnosis:

•

Cylinder Compression Pressure Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).

•

Cylinder Combustion Pressure Leakage Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).

•

Engine Cylinder Head Gasket Failure Diagnosis (Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNOSIS AND
TESTING).

•

Intake Manifold Leakage Diagnosis (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - DIAGNOSIS
AND TESTING).

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE

CONDITION

POSSIBLE CAUSE

CORRECTION

ENGINE WILL NOT START

1. Weak battery

1. Charge or replace as necessary.

2. Corroded or loose battery
connections.

2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to the terminals.

3. Faulty starter.

3. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND
TESTING).

4. Incorrect spark plug gap.

4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).

5. Dirt or water in fuel system.

5. Clean system and replace fuel
filter.

6. Faulty fuel pump, relay or wiring.

6. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)

ENGINE STALLS OR ROUGH IDLE

1. Idle speed set to low.

1. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)

2. Vacuum leak.

2. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.

3. Incorrect engine timing.

3. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD
PROCEDURE).

9 - 1322

ENGINE - 5.7L SERVICE INFORMATION

HB

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