Content .. 461 462 463 464 ..

Dodge Durango (DN). Manual - part 463

ASSEMBLE

(1) Install pump rotors and shaft, using new parts

as required.

(2) Position the oil pump cover onto the pump

body. Tighten cover bolts to 11 N·m (95 in. lbs.)
torque.

(3) Install the relief valve and spring. Insert the

cotter pin.

(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling

rotor cavity with engine oil.

CLEANING AND INSPECTION

CYLINDER HEAD COVER

CLEANING

Clean cylinder head cover gasket surface.
Clean head rail, if necessary.

INSPECTION

Inspect cover for distortion and straighten, if nec-

essary.

Check the gasket for use in head cover installation.

If damaged, use a new gasket.

CYLINDER HEAD ASSEMBLY

CLEANING

Clean all surfaces of cylinder block and cylinder

heads.

Clean cylinder block front and rear gasket surfaces

using a suitable solvent.

INSPECTION

Inspect all surfaces with a straightedge if there is

any reason to suspect leakage. If out-of-flatness
exceeds 0.00075 mm/mm (0.00075 inch/inch) times
the span length in inches in any direction, either
replace head or lightly machine the head surface.

FOR EXAMPLE: A 305 mm (12 inch) span is

0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 X 0.00075 (12 X 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept-
able.

The

cylinder

head

surface

finish

should

1.78-3.00 microns (70-125 microinches).

PISTON AND CONNECTING ROD ASSEMBLY

INSPECTION

Check the crankshaft connecting rod journal for

excessive wear, taper and scoring.

Check the cylinder block bore for out-of-round,

taper, scoring and scuffing.

Check the pistons for taper and elliptical shape

before they are fitted into the cylinder bore (Fig. 83).

OIL PAN

CLEANING

Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear

main cap oil pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.

If present, trim excess sealant from inside the

engine.

Clean oil pan in solvent and wipe dry with a clean

cloth.

Clean oil screen and pipe thoroughly in clean sol-

vent. Inspect condition of screen.

INSPECTION

Inspect oil drain plug and plug hole for stripped or

damaged threads. Repair as necessary.

Inspect oil pan mounting flange for bends or distor-

tion. Straighten flange, if necessary.

OIL PUMP

INSPECTION

Mating surface of the oil pump cover should be

smooth. Replace pump assembly if cover is scratched
or grooved.

Lay a straightedge across the pump cover surface

(Fig. 84). If a 0.038 mm (0.0015 inch) feeler gauge
can be inserted between cover and straightedge,
pump assembly should be replaced.

Fig. 83 Piston Measurements

1 – 49.53 mm

(1.95 IN.)

9 - 182

5.9L ENGINE

DISASSEMBLY AND ASSEMBLY (Continued)

Measure thickness and diameter of OUTER rotor.

If outer rotor thickness measures 20.9 mm (0.825
inch) or less or if the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 85).

If inner rotor measures 20.9 mm (0.825 inch) or

less, replace inner rotor and shaft assembly (Fig. 86).

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

25.007 - 25.015 mm

BORE

(.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. 84 Checking Oil Pump Cover Flatness

1 – COVER
2 – STRAIGHT EDGE
3 – FEELER GAUGE

Fig. 85 Measuring Outer Rotor Thickness

Fig. 86 Measuring Inner Rotor Thickness

5.9L ENGINE

9 - 183

CLEANING AND INSPECTION (Continued)

Slide outer rotor into pump body. Press rotor to the

side

with

your

fingers

and

measure

clearance

between rotor and pump body (Fig. 87). If clearance
is 0.356 mm (0.014 inch) or more, replace oil pump
assembly.

Install inner rotor and shaft into pump body. If

clearance between inner and outer rotors is 0.203
mm (0.008 inch) or more, replace shaft and both
rotors (Fig. 88).

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).

If oil pressure was low and pump is within specifi-

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

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

Fig. 90 Proper Installation of Retainer Cap

1 – RETAINER CAP
2 – CHAMFER
3 – COTTER KEY

9 - 184

5.9L ENGINE

CLEANING AND INSPECTION (Continued)

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.

SPECIFICATIONS

5.9L ENGINE SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Engine Type

90° V-8 OHV

Bore and Stroke

101.6 x 90.9 mm

(4.00 x 3.58 in.)

Displacement

5.9L (360 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

Cylinder Head

Cast Iron

Crankshaft

Nodular Iron

Camshaft

Nodular Cast Iron

Combustion Chambers

Wedge -

High Swirl Valve

Shrouding

Pistons

Aluminum Alloy w/strut

Connecting Rods

Forged Steel

Cylinder Compression

689.5 kPa

Pressure (Min.)

(100 psi)

DESCRIPTION

SPECIFICATION

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.)

No. 5

39.688 – 39.713 mm

(1.5625 – 1.5635 in.)

5.9L ENGINE

9 - 185

CLEANING AND INSPECTION (Continued)

Content .. 461 462 463 464 ..