5.7L Engine - Service Information: Other Dodge Durango II

STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS

Damaged or worn threads can be repaired. Essentially, this repair consists of

1. Drilling out worn or damaged threads.
2. Tapping the hole with a special Heli-Coil Tap, or equivalent.
3. Installing an insert into the tapped hole to bring the hole back to its original thread size.

STANDARD PROCEDURE - HYDROSTATIC LOCK

When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below.

1. Perform the Fuel Pressure Release Procedure. Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(ref-564649-S02344868012013070500000) .
2. Disconnect the negative cable(s) from the battery.
3. Inspect air cleaner, induction system, and intake manifold to ensure system is dry and clear of foreign material.
4. Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the cylinder head. Remove the spark plugs.
5. With all spark plugs removed, rotate the crankshaft using a breaker bar and socket.
6. identify the fluid in the cylinders (coolant, fuel, oil, etc.).
7. Be sure all fluid has been removed from the cylinders.
8. Repair engine or components as necessary to prevent this problem from occurring again.
9. Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
10. Install new spark plugs. Tighten the spark plugs to 41 N.m (30 ft. lbs.) torque.
11. Drain engine oil. Remove and discard the oil filter.
12. Install the drain plug. Tighten the plug to 34 N.m (25 ft. lbs.) torque.
13. Install a new oil filter.
14. Fill engine crankcase with the specified amount and grade of oil. (Refer to «LUBRICATION»(ref-212816-S26295309092005122700000) ).
15. Connect the negative cable(s) to the battery.
16. Start the engine and check for any leaks.

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATION

PISTONS

PISTONS SPECIFICATION

PISTON PINS

PISTON PINS SPECIFICATION

PISTON RINGS

PISTON RINGS SPECIFICATION

CONNECTING RODS

CONNECTING RODS SPECIFICATION

CRANKSHAFT

CRANKSHAFT SPECIFICATION

CAMSHAFT

CAMSHAFT SPECIFICATION

VALVE TIMING

VALVE TIMING SPECIFICATION

CYLINDER HEAD

CYLINDER HEAD SPECIFICATION

HYDRAULIC TAPPETS

HYDRAULIC TAPPETS SPECIFICATION

VALVES

VALVES SPECIFICATION

VALVE SPRING

VALVE SPRING SPECIFICATION

OIL PUMP

OIL PUMP SPECIFICATION

OIL PRESSURE

OIL PRESSURE SPECIFICATION

Filter Element Only

Housing removal is not necessary for element (filter) replacement.

1. Loosen clamp and disconnect air duct at air cleaner cover.
2. Pry over 4 spring clips from housing cover (spring clips retain cover to housing).
3. Release housing cover from locating tabs on housing and remove cover.
4. Remove air cleaner element (filter) from housing.
5. Clean inside of housing before replacing element.

Scheme 349

1. Loosen clamp and disconnect air duct at air cleaner cover.
2. Lift entire housing assembly from 4 locating pins.

Scheme 350

1. Install filter element into housing.
2. Position housing cover into housing locating tabs.
3. Pry up 4 spring clips and lock cover to housing.
4. Install air duct to air cleaner cover and tighten hose clamp to 3 N.m (30 in. lbs.) torque.
5. If any other hose clamps were removed from air intake system, tighten them to 3.4 N.m (30 in. lbs.) torque.
6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 N.m (40 in. lbs.) torque.

COOLING SYSTEM TESTER METHOD

Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester's pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.

CLEANING

Clean all surfaces of cylinder block and cylinder heads.

Clean cylinder block front and rear gasket surfaces using a suitable solvent.

STANDARD PROCEDURE - REFACING

Note. Valve seats that are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced.

Note. When refacing valves and valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained.

Scheme 351

1. Using a suitable dial indicator measure the center of the valve seat Total run out must not exceed 0.051 mm (0.002 in).
2. Apply a small amount of Prussian blue to the valve seat, insert the valve into the cylinder head, while applying light pressure on the valve rotate the valve. Remove the valve and examine the valve face. If the blue is transferred below the top edge of the valve face, lower the valve seat using a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat using a 65 degree stone.
3. When the seat is properly positioned the width of the intake seat must be 1.018 - 1.62 mm (0.0464 - 0.0637 in.) and the exhaust seat must be 1.48 - 1.92 mm (0.058 - 0.075 in.).
4. Check the valve spring installed height after refacing the valve and seat. The installed height for both intake and exhaust valve springs must not exceed 46.0 mm (1.81 in.). VALVE FACE AND VALVE SEAT ANGLE CHART VALVE FACE AND VALVE SEAT ANGLE SPECIFICATION DESCRIPTION SPECIFICATION SEAT WIDTH INTAKE 1.018 - 1.62 mm(0.0464 - 0.0637 in.) EXHAUST 1.48 - 1.92 mm(0.058 - 0.075 in.) FACE ANGLE(INT. AND EXT.) 45° - 45 1/2° SEAT ANGLE(INT. AND EXT.) 44 1/2° - 45°
5. The valve seat must maintain an angle of 44.5 - 45.0 degrees angle.
6. The valve face must maintain a face angle of 45.0 - 45.5 degrees angle.

Thoroughly clean the oil pan and engine block gasket surfaces.

Use compressed air to clean out

1. The galley at the oil filter adaptor hole.
2. The front and rear oil galley holes.
3. The feed holes for the crankshaft main bearings.

Once the block has been completely cleaned, apply Loctite PST pipe sealant with Teflon 592 to the threads of the front and rear oil galley plugs. Tighten the 1/4 inch NPT plugs to 20 N.m (177 in. lbs.) torque. Tighten the 3/8 inch NPT plugs to 27 N.m (240 in. lbs.) torque.

Scheme 352

1. It is mandatory to use a dial bore gauge to measure each cylinder bore diameter. To correctly select the proper size piston, a cylinder bore gauge, capable of reading in 0.003 mm (.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
2. Measure the inside diameter of the cylinder bore at three levels below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft and then take two additional reading.
3. Measure the cylinder bore diameter crosswise to the cylinder block near the top of the bore. Repeat the measurement near the middle of the bore, then repeat the measurement near the bottom of the bore.
4. Determine taper by subtracting the smaller diameter from the larger diameter.
5. Rotate measuring device 90° and repeat steps above.
6. Determine out-of-roundness by comparing the difference between each measurement.
7. If cylinder bore taper does not exceed 0.025 mm (0.001 inch) and out-of-roundness does not exceed 0.025 mm (0.001 inch), the cylinder bore can be honed. If the cylinder bore taper or out- of-round condition exceeds these maximum limits, the cylinder block must be replaced. A slight amount of taper always exists in the cylinder bore after the engine has been in use for a period of time.

MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)

Crankshaft removed from the cylinder block.

Clean the oil off the main bearing journal.

Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal.

The maximum allowable taper is 0.008mm (0.0004 inch.) and maximum out of round is 0.005mm (0.0002 inch).

Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance.

CRANKSHAFT MAIN BEARING SELECTION

The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft counterweight has grade identification marks stamped into it. These marks are read from left to right, corresponding with journal number 1, 2, 3, 4 and 5.

Note. Service main bearings are coded. These codes identify what size (grade) the bearing is.

MAIN BEARING SELECTION CHART

MAIN BEARING REFERENCE

HIGH

If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily.

LOW

Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length, which allows valves to seat noisily. Any leaks on intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets to be bled out.

1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry.
2. Use a wood or plastic scraper to clean the ring land grooves.

STANDARD PROCEDURE - PISTON RING FITTING

Before reinstalling used rings or installing new rings, the ring clearances must be checked.

Scheme 353

Scheme 354

Scheme 355

Scheme 356

Scheme 357

1. Wipe the cylinder bore clean.
2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12mm (0.50 inch.) from bottom of cylinder bore.
3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder.
4. Using a feeler gauge check the ring end gap. Replace any rings not within specification. PISTON RING SIDE CLEARANCE NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs.
5. Measure the ring side clearance as shown make sure the feeler gauge fits snugly between the ring land and the ring. Replace any ring not within specification.
6. Rotate the ring around the piston, the ring must rotate in the groove with out binding. PISTON RING SPECIFICATION CHART PISTON RING SPECIFICATION Ring Position Groove Clearance Maximum Clearance Upper Ring 0.6715-.0.7105mm (0.0264- 0.0279 in.) 0.11mm (0.004 in.) Intermediate Ring 0.5455-0.6245mm (0.0214-0.0245 in.) 0.10mm (0.004 in.) Ring Position Ring Gap Wear Limit Upper Ring 0.23-0.38mm (0.0090-0.0149 in.) 0.43mm (0.017 in.) Intermediate Ring 0.35-0.60mm (0.0137-0.0236 in.) 0.74mm (0.029 in.) Oil Control Ring (Steel Rail) 0.015-0.66mm (0.0059- 0.0259 in.) 1.55mm (0.061 in.)
7. The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: Oil ring expander. Lower oil ring side rail. Upper oil ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring.
8. Install the oil ring expander.
9. Install upper side rail by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail.
10. Install No. 2 intermediate piston ring using a piston ring installer.
11. Install No. 1 upper piston ring using a piston ring installer.
12. Position piston ring end gaps as shown in. It is important that expander ring gap is at least 45° from the side rail gaps, but not on the piston pin center or on the thrust direction.

AUTOMATIC TRANSMISSION

Scheme 358

1. Position the structural cover in the vehicle.
2. Install all four bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time.
3. Install the four cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover.
4. Torque the (4)structural dust cover bolts that go into the transmission to 6-11 N.m (50-100 in.lbs.).
5. Torque the (4) structural dust cover bolts that go into the engine block to 6-11 N.m (50-100 in.lbs.).
6. Starting with the two rear cover-to-engine bolts, tighten bolts (1) to 54 N.m (40 ft. lbs.), then tighten bolts (2) and (3) to 54 N.m ( 40 ft. lbs.) in the sequence shown.
7. Install the exhaust pipe on left hand exhaust manifold.
8. Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20-26 N.m (15-20 ft. lbs.).

MANUAL TRANSMISSION

Scheme 359

1. Position the structural cover in the vehicle. CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover, and engine noise.
2. Install all bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time.
3. Install the cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against the corner formed by the engine and the transmission clutch housing during tightening sequence. Failure to do so may cause damage to the cover and engine noise.
4. Torque the (2)structural dust cover bolts that go into the clutch housing to 6-11 N.m (50-100 in.lbs.).
5. Torque the (4) structural dust cover bolts that go into the engine block to 6-11 N.m (50-100 in.lbs.).
6. Torque the structural cover bolt that is closest to the rear face of block on the passenger side of block to 54 N.m (40 ft. lbs.).
7. Torque the structural cover bolt that is closest to the front face of block on the drivers side to 54 N.m (40 ft. lbs.).
8. Torque the remaining (2) structural cover bolts that go into the block in an "X" pattern to 54 N.m (40 ft. lbs.).
9. Torque the structural cover bolts that go into the clutch housing to 54 N.m (40 ft. lbs.).
10. Torque the 7/16 inch engine block to clutch housing bolts to 68 N.m (50 ft. lbs.).

2WD

1. Disconnect negative battery cable.
2. Raise vehicle.
3. Remove engine mount through bolts.
4. Raise engine using engine support fixture special tool # 8534.
5. Remove engine mount to insulator bolts.
6. Remove insulator from engine.

Scheme 360

1. Disconnect the negative cable from the battery.
2. Raise the vehicle.
3. Remove the skid plate.
4. Remove the front crossmember.
5. Remove the engine oil filter.
6. Support the engine using engine support fixture, special tool # 8534.
7. Support the front axle with a suitable jack.
8. Remove the (4) bolts that attach the engine mounts to the front axle.
9. Remove the (3) bolts that attach the front axle to the left engine bracket.
10. Lower the front axle.
11. Remove the (6) through bolts
12. Raise the engine far enough to be able to remove the left and right engine mounts.
13. Remove the engine mounts.

1. Install insulator on the engine. NOTE: For mount to engine block and left engine bracket to front axle bolts, apply Mopar® Lock and Seal Adhesive, Medium Strength Threadlocker.
2. Install upper and lower mount mounting bolts. Tighten bolts to 61 N.m (45 ft. lbs.).
3. Lower the engine using engine support fixture special tool # 8534.
4. Install mount through bolts.
5. Tighten through bolts on both sides to 61 N.m (45 ft. lbs.).
6. Lower vehicle.
7. Connect negative battery cable.

4WD

Note. For mount to engine block and left engine bracket to front axle bolts, apply Mopar® Lock and Seal Adhesive, Medium Strength Threadlocker.

Scheme 361

1. Install the right and left side engine mounts to the front axle. Torque nuts to 94 N.m (70 ft. lbs.).
2. Raise the front axle into the frame and install the left and right side through bolts. Torque nuts to 94 N.m (70 ft. lbs.).
3. Insert the two upper through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
4. Lower the engine using engine support fixture special tool # 8534, until the left and right side engine brackets rest on the through bolts, and the lower engine bracket through holes align with the engine mounts, and the left engine bracket holes align with the front axle slots.
5. Loose assemble the (3) bolts that attach the front axle to the left engine bracket.
6. Loose assemble the lower through bolts.
7. Torque the nuts for the (4) through bolts to 101 N.m (75 ft. lbs.).
8. Torque the (3) bolts that attach the front axle to the left engine bracket to 101 N.m (75 ft. lbs.).
9. Install the engine oil filter, if removed.
10. Install the front crossmember.
11. Install the skid plate.
12. Lower the vehicle.
13. Reconnect the negative battery cable.

Scheme 362

1. Raise the vehicle on a hoist.
2. Using a suitable jack, support transmission.
3. Remove the nuts from the transmission mount.
4. Remove the bolts that attach the transmission mount to the engine bracket.
5. Raise the transmission enough to remove the mount from the crossmember.
6. Remove the mount.

STANDARD PROCEDURE - ENGINE OIL SERVICE

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Service Grade Certified. MOPAR® provides engine oils that conform to this service grade.

SAE VISCOSITY

An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 in the 5.7L engines. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation.

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.

OIL LEVEL INDICATOR (DIPSTICK)

The engine oil level indicator is located at the left hand of the engine on the 5.7L engines.

ENGINE OIL CHANGE

Change engine oil at mileage and time intervals described in Maintenance Schedules .

Run engine until achieving normal operating temperature.

1. Position the vehicle on a level surface and turn engine off.
2. Hoist and support vehicle on safety stands.
3. Remove oil fill cap.
4. Place a suitable drain pan under crankcase drain.
5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged.
6. Install drain plug in crankcase. Torque to 34 N.m ( 25 ft. lbs.).
7. Lower vehicle and fill crankcase with specified type and amount of engine oil described in this section.
8. Install oil fill cap.
9. Start engine and inspect for leaks.
10. Stop engine and inspect oil level.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING at beginning of this section.

4X2

1. Disconnect the negative battery cable.
2. Loosen both left and right side engine mount through bolts. Do not remove bolts.
3. Install engine support fixture special tool # 8534. Do not raise engine at this time.
4. Remove the structural dust cover, if equipped.
5. Remove fan and fan shroud.
6. Drain engine oil.
7. Remove the front crossmember .
8. Raise engine using special tool # 8534 to provide clearance to remove oil pan. NOTE: Do not pry on oil pan or oil pan gasket. Gasket is integral to engine windage tray and does not come out with oil pan. NOTE: If more clearance is needed to remove oil pan, the transmission mount can be removed, and the transmission raised to gain clearance.
9. Remove the oil pan mounting bolts and oil pan.
10. Unbolt oil pump pickup tube and remove tube.
11. Inspect the integral windage tray and gasket and replace as needed.

4X4

1. Follow all steps for 4X2 removal.
2. Unbolt and lower the steering rack, without disconnecting the lines. NOTE: The front axle must be lowered to remove the oil pan on 4X4 vehicles.
3. Remove the front driveshaft at the axle. Mark for reassembly.
4. Support the front axle.
5. Remove the right and left axle to mount, bolts.
6. Lower axle.
7. Remove the oil pan mounting bolts and oil pan.
8. Unbolt oil pump pickup tube and remove tube.
9. Inspect the integral windage tray and gasket and replace as needed.

1. Wash all parts in a suitable solvent.

Note. There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced.

Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry.

EXHAUST MANIFOLD

1. Disconnect negative battery cable.
2. Raise vehicle.
3. Remove exhaust pipe to manifold bolts.
4. Lower vehicle.
5. Install engine support fixture special tool #8534.
6. Raise engine enough to remove manifolds. CAUTION: Do not damage engine harness while raising the engine.
7. Remove heat shield.
8. Remove manifold bolts.
9. Remove manifold and gasket.

Clean mating surfaces on cylinder head and manifold. Wash with solvent and blow dry with compressed air.

1. Install manifold gasket and manifold.
2. Install manifold bolts and tighten to 25 N.m (18 ft. lbs.).
3. Install heat shield and tighten nuts to 15 N.m (11 ft. lbs.).
4. Lower engine. CAUTION: Do not damage engine harness while lowering the engine.
5. Remove engine support fixture from engine.
6. Raise vehicle.
7. Tighten right and left side engine mount through bolts.
8. Install exhaust flange to pipe bolts.
9. Lower vehicle.
10. Connect negative battery cable.