Dodge Durango (DN). Manual - part 442

ring gap should be between 0.508-0.762 mm (0.020-
0.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).

erly filed to the correct dimension. Rings with
excess gaps should not be used.
(2) Install rings and confirm ring side clearance:

(a) Install oil rings being careful not to nick or

scratch the piston. Install the oil control rings
according to instructions in the package. It is not
necessary to use a tool to install the upper and
lower rails. Insert oil rail spacer first, then side
rails.

(b) Install the second compression rings using

Installation Tool C-4184. The compression rings
must be installed with the identification mark face

up (toward top of piston) and chamfer facing down.
An identification mark on the ring is a drill point,
a stamped letter “O”, an oval depression or the
word TOP (Fig. 26) (Fig. 28).

pression ring with the chamfer facing up (Fig. 27)
(Fig. 28). An identification mark on the ring is a
drill point, a stamped letter “O”, an oval depression
or the word TOP facing up.

(d) Measure side clearance between piston ring

and ring land. Clearance should be 0.074-0.097 mm
(0.0029-0.0038 inch) for the compression rings. The
steel rail oil ring should be free in groove, but
should not exceed 0.246 mm (0.0097 inch) side
clearance.

(e) Pistons with insufficient or excessive side

clearance should be replaced.

PISTON MEASUREMENT CHART

PISTON

A DIA = PISTON

BORE

SIZE

DIAMETER

MIN.

MAX.

MIN.

MAX.

(in.)

mm (in.)

—

101.580

101.592

101.605

101.618

(3.9992)

(3.9997)

(4.0002)

(4.0007)

101.592

101.605

101.618

101.630

(3.9997)

(4.0002)

(4.0007)

(4.0012)

101.605

101.618

101.630

101.643

(4.0002)

(4.0007)

(4.0012)

(4.0017)

—

DESCRIPTION

SPECIFICATION

PISTON PIN BORE

25.007 - 25.015 mm

(.9845 -.9848 in.)

RING GROOVE

HEIGHT

OIL RAIL

4.033 - 4.058 mm

(.1588 -.1598 in.)

COMPRESSION

RAIL

1.529 - 1.554 mm

(.0602 -.0612 in.)

TOTAL FINISHED

470.8

2 grams

WEIGHT

(16.607

.0706 ounces)

Fig. 26 Second Compression Ring Identification

(Typical)

1 – SECOND COMPRESSION RING (BLACK CAST IRON)
2 – CHAMFER
3 – TWO DOTS

Fig. 27 Top Compression Ring Identification

(Typical)

1 – TOP COMPRESSION RING (GRAY IN COLOR)
2 – CHAMFER
3 – ONE DOT

5.2L ENGINE

9 - 99

SERVICE PROCEDURES (Continued)

CONNECTING ROD BEARINGS—FITTING

Fit all rods on a bank until completed. DO NOT

alternate from one bank to another, because connect-
ing rods and pistons are not interchangeable from
one bank to another.

The bearing caps are not interchangeable and

should be marked at removal to ensure correct
assembly.

Each bearing cap has a small V-groove across the

parting face. When installing the lower bearing shell,
make certain that the V-groove in the shell is in line
with the V-groove in the cap. This provides lubrica-
tion of the cylinder wall in the opposite bank.

The bearing shells must be installed so that the

tangs are in the machined grooves in the rods and
caps.

Limits of taper or out-of-round on any crankshaft

journals should be held to 0.025 mm (0.001 inch).
Bearings are available in 0.025 mm (0.001 inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under-
size. Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing half. DO
NOT file the rods or bearing caps.

CRANKSHAFT MAIN BEARINGS—FITTING

Bearing caps are not interchangeable and should

be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter-
changeable. Lower main bearing halves of No.2 and 4
are interchangeable.

Upper and lower No.3 bearing halves are flanged

to carry the crankshaft thrust loads. They are NOT
interchangeable with any other bearing halves in the
engine (Fig. 30). Bearing shells are available in stan-
dard and the following undersizes: 0.25 mm (0.001
inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
Never install an undersize bearing that will reduce
clearance below specifications.

REMOVAL AND INSTALLATION

ENGINE MOUNTS—FRONT

REMOVAL

On 4WD vehicles the engine front support brackets

attach directly to engine block and the axle housing.
The brackets provide a solid interconnection for these
units (Fig. 31) (Fig. 32). Engine must be supported
during any service procedures involving the front
support assemblies.

Fig. 28 Compression Ring Chamfer Location

(Typical)

1 – CHAMFER
2 – TOP COMPRESSION RING
3 – SECOND COMPRESSION RING
4 – PISTON
5 – CHAMFER

Fig. 29 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. 30 Main Bearing Identification

9 - 100

5.2L ENGINE

SERVICE PROCEDURES (Continued)

(1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist.
(3) Install engine lifting (support) fixture.
(4) Remove front axle assembly. (Refer to Group 3,

Differential and Driveline in this publication.)

(5)

Left mount insulator only. Remove starter

wires and starter motor assembly.

(6) Remove insulator to frame through bolt (Fig.

33).

(7) Raise engine slightly.
(8) Remove upper insulator to support bracket

stud nut and insulator to support through bolt.

(9) Remove engine mount insulator (Fig. 31) (Fig.

32).

(10) If engine support bracket is to be removed/re-

placed, remove support bracket to transmission bell
housing bolt(s) and three (3) support bracket to
engine block bolts. Remove support bracket (Fig. 31)
(Fig. 32).

INSTALLATION—4WD

(1) If engine support brackets were removed,

install them and their fasteners (Fig. 31) (Fig. 32).
Tighten support bracket to block bolts to 41 N·m (30
ft. lbs.). Tighten support bracket to transmission bell-
housing bolt(s) to 88 N·m (65 ft. lbs.).

(2) Install Engine mount insulator and tighten

insulator to support bracket nut to 41 N·m (30 ft.
lbs.). Tighten insulator to support bracket through
bolt nut to 102 N·m (75 ft. lbs.).

(3) Lower engine and install insulator to frame

through bolt and nut (Fig. 33). Tighten nut to 95 N·m
(70 ft. lbs.).

(4) Install

starter

motor

and

mounting

bolts.

Tighten bolts to 68 N·m (50 ft. lbs.).

(5) Connect starter wires.
(6) Remove engine lifting (support) fixture.
(7) Install front axle assembly. (Refer to Group 3,

Differential and Driveline).

(8) Lower the vehicle.
(9) Connect the negative cable to the battery.

Fig. 31 Right Engine Mount Insulator and Support

Bracket

1 – ENGINE SUPPORT BRACKET
2 – INSULATOR
3 – FRONT AXLE

Fig. 32 Left Engine Mount Insulator and Support

Bracket

1 – ENGINE SUPPORT BRACKET
2 – INSULATOR
3 – FRONT AXLE

5.2L ENGINE

9 - 101

REMOVAL AND INSTALLATION (Continued)

ENGINE MOUNT—REAR

REMOVAL

(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Support the transmission with a transmission

jack.

(4) Remove stud nuts holding the insulator to the

crossmember (Fig. 34).

(5) Raise rear of transmission SLIGHTLY.
(6) Remove bolts holding the insulator to the insu-

lator bracket (Fig. 34). Remove the insulator.

INSTALLATION

(1) If the insulator bracket was removed, install

the bracket to the transmission (Fig. 34). Tighten the
bolts to 28 N·m (250 in. lbs.) torque.

(2) Install the bolts holding insulator to insulator

bracket. Tighten the bolts to 28 N·m (250 in. lbs.)
torque.

(3) Lower rear of transmission while aligning the

insulator studs into the mounting support bracket.

Install stud nuts and tighten to 28 N·m (250 in. lbs.)
torque.

(4) Remove the transmission jack.
(5) Lower the vehicle.
(6) Connect the negative cable to the battery.

ENGINE ASSEMBLY

REMOVAL

(1) Scribe hood hinge outlines on hood. Remove the

hood.

(2) Disconnect the battery negative cable.
(3) Drain cooling system (refer to Group 7, Cooling

System for the proper procedure).

(4) Remove the air cleaner.
(5) Disconnect the radiator and heater hoses.

Remove radiator (refer to Group 7, Cooling System
for the correct procedures).

(6) Set fan shroud aside.
(7) Disconnect the vacuum supply lines from the

intake manifold.

(8) Remove the distributor cap and wires.

Fig. 33 Engine Mount Insulator at Frame

1 – NUT
2 – ENGINE SUPPORT BRACKET
3 – INSULATOR
4 – NUT
5 – THROUGH BOLT
6 – FRAME
7 – FRONT AXLE

Fig. 34 Rear Mount Insulator

1 – AUTOMATIC TRANSMISSION
2 – INSULATOR BRACKET
3 – INSULATOR
4 – CROSSMEMBER

9 - 102

5.2L ENGINE

REMOVAL AND INSTALLATION (Continued)

Content .. 440 441 442 443 ..