Dodge Durango (DN). Manual - part 462

(2) Hold the oil pump base flush against mating

surface on No.5 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
N·m (30 ft. lbs.) torque.

(3) Install the oil pan.

CRANKSHAFT OIL SEAL—FRONT

The oil seal can be replaced without removing the

timing chain cover provided the cover is not mis-
aligned.

(1) Disconnect the negative cable from the battery.
(2) Remove vibration damper.
(3) If front seal is suspected of leaking, check front

oil seal alignment to crankshaft. The seal installa-
tion/alignment tool 6635, should fit with minimum
interference. If tool does not fit, the cover must be
removed and installed properly.

(4) Place a suitable tool behind the lips of the oil

seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal bore of cover.

(5) Place the smaller diameter of the oil seal over

Front Oil Seal Installation Tool 6635 (Fig. 74). Seat
the oil seal in the groove of the tool.

(6) Position the seal and tool onto the crankshaft

(Fig. 75).

(7) Using the vibration damper bolt, tighten the

bolt to draw the seal into position on the crankshaft
(Fig. 76).

(8) Remove the vibration damper bolt and seal

installation tool.

(9) Inspect

the

seal

flange

the

vibration

damper.

(10) Install the vibration damper.
(11) Connect the negative cable to the battery.

Fig. 74 Placing Oil Seal on Installation Tool 6635

1 – CRANKSHAFT FRONT OIL SEAL
2 – INSTALL THIS END INTO SPECIAL TOOL 6635

Fig. 75 Position Tool and Seal onto Crankshaft

1 – SPECIAL TOOL 6635
2 – OIL SEAL
3 – TIMING CHAIN COVER

Fig. 76 Installing Oil Seal

1 – SPECIAL TOOL 6635
2 – TIMING CHAIN COVER

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5.9L ENGINE

REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT OIL SEALS—REAR

The service seal is a 2 piece, viton seal. The upper

seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
The lower seal half can only be installed with the
rear main bearing cap removed.

UPPER SEAL —CRANKSHAFT REMOVED

REMOVAL

(1) Remove the crankshaft. Discard the old upper

seal.

INSTALLATION

(1) Clean the cylinder block rear cap mating sur-

face. Make sure the seal groove is free of debris.

(2) Lightly oil the new upper seal lips with engine

oil.

(3) Install the new upper rear bearing oil seal with

the white paint facing towards the rear of the engine.

(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine

oil.

(6) Install the new lower rear bearing oil seal into

the bearing cap with the white paint facing towards
the rear of the engine.

(7) Apply 5 mm (0.20 in) drop of Mopar

t Gasket

Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 77). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.

(8) To align the bearing cap, use cap slot, align-

ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.

(9) Clean and oil all cap bolts. Install all main

bearing caps. Install all cap bolts and alternately
tighten to 115 N·m (85 ft. lbs.) torque.

(10) Install oil pump.
(11) Apply Mopar

t Silicone Rubber Adhesive Seal-

ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 78).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.

(12) Install new front crankshaft oil seal.
(13) Immediately install the oil pan.

UPPER SEAL —CRANKSHAFT INSTALLED

REMOVAL

(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-

ing cap.

(3) Remove the rear main bearing cap. Remove

and discard the old lower oil seal.

(4) Carefully remove and discard the old upper oil

seal.

INSTALLATION

(1) Clean the cylinder block mating surfaces before

oil seal installation. Check for burr at the oil hole on
the cylinder block mating surface to rear cap.

(2) Lightly oil the new upper seal lips with engine

oil. To allow ease of installation of the seal, loosen at

Fig. 77 Sealant Application to Bearing Cap

1 – MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS
2 – LOCTITE 518 (OR EQUIVALENT)
3 – CAP ALIGNMENT SLOT
4 – REAR MAIN BEARING CAP

Fig. 78 Apply Sealant to Bearing Cap to Block Joint

1 – MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE

TIP

2 – SEALANT APPLIED
3 – CYLINDER BLOCK
4 – REAR MAIN BEARING CAP

5.9L ENGINE

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REMOVAL AND INSTALLATION (Continued)

least the 2 main bearing caps forward of the rear
bearing cap.

(3) Rotate the new upper seal into the cylinder

block being careful not to shave or cut the outer sur-
face of the seal. To assure proper installation, use the
installation tool provided with the kit. Install the
new seal with the white paint facing towards the
rear of the engine.

(4) Install the new lower rear bearing oil seal into

the bearing cap with the white paint facing towards
the rear of the engine.

(5) Apply 5 mm (0.20 in) drop of Mopar

t Gasket

(6) To align the bearing cap, use cap slot, align-

ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.

(7) Install the rear main bearing cap with cleaned

and oiled cap bolts. Alternately tighten ALL cap bolts
to 115 N·m (85 ft. lbs.) torque.

(8) Install oil pump.
(9) Apply Mopar

t Silicone Rubber Adhesive Seal-

(10) Immediately install the oil pan.

LOWER SEAL

REMOVAL

(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-

ing cap.

(3) Remove the rear main bearing cap and discard

the old lower seal.

INSTALLATION

(1) Clean the rear main cap mating surfaces

including the oil pan gasket groove.

(2) Carefully install a new upper seal (refer to

Upper Seal Replacement - Crankshaft Installed pro-
cedure above).

(3) Lightly oil the new lower seal lips with engine

oil.

(4) Install a new lower seal in bearing cap with

the white paint facing the rear of engine.

(5) Apply 5 mm (0.20 in) drop of Mopar

t Gasket

Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 77). DO NOT over apply sealant or

allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.

(6) To align the bearing cap, use cap slot, align-

ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.

(7) Install the rear main bearing cap with cleaned

and oiled cap bolts. Alternately tighten the cap bolts
to 115 N·m (85 ft. lbs.) torque.

(8) Install oil pump.
(9) Apply Mopar

t Silicone Rubber Adhesive Seal-

(10) Immediately install the oil pan.

ENGINE CORE OIL AND CAMSHAFT PLUGS

Engine core plugs have been pressed into the oil

galleries behind the camshaft thrust plate (Fig. 79).
This will reduce internal leakage and help maintain
higher oil pressure at idle.

REMOVAL

(1) Using a blunt tool such as a drift or a screw-

driver and a hammer, strike the bottom edge of the
cup plug (Fig. 80).

(2) With the cup plug rotated, grasp firmly with

pliers or other suitable tool and remove plug (Fig.
80).

Fig. 79 Location of Cup Plugs in Oil Galleries

1 – CUP PLUGS

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5.9L ENGINE

REMOVAL AND INSTALLATION (Continued)

INSTALLATION

Thoroughly clean inside of cup plug hole in cylin-

der block or head. Be sure to remove old sealer.

Be certain the new plug is cleaned of all oil or

grease.

(1) Coat edges of plug and core hole with Mopar

Gasket Maker, or equivalent.

CAUTION: DO NOT drive cup plug into the casting,
as restricted coolant flow can result and cause seri-
ous engine problems.

(2) Using proper plug drive, drive cup plug into

hole. The sharp edge of the plug should be at least
0.50 mm (0.020 in.) inside the lead-in chamfer.

(3) It is not necessary to wait for curing of the

sealant. The cooling system can be filled and the
vehicle placed in service immediately.

DISASSEMBLY AND ASSEMBLY

OIL PUMP

DISASSEMBLE

(1) Remove the relief valve as follows:

(a) Remove cotter pin. Drill a 3.175 mm (1/8

inch) hole into the relief valve retainer cap and
insert a self-threading sheet metal screw.

(b) Clamp screw into a vise and while support-

ing oil pump, remove cap by tapping pump body
using a soft hammer. Discard retainer cap and
remove spring and relief valve (Fig. 81).

(2) Remove oil pump cover (Fig. 82).
(3) Remove pump outer rotor and inner rotor with

shaft (Fig. 82).

(4) Wash all parts in a suitable solvent and inspect

carefully for damage or wear.

Fig. 80 Core Hole Plug Removal

1 – CYLINDER BLOCK
2 – REMOVE PLUG WITH PLIERS
3 – STRIKE HERE WITH HAMMER
4 – DRIFT PUNCH
5 – CUP PLUG

Fig. 81 Oil Pressure Relief Valve

1 – OIL PUMP ASSEMBLY
2 – COTTER PIN
3 – RELIEF VALVE
4 – RETAINER CAP
5 – SPRING

Fig. 82 Oil Pump

1 – INNER ROTOR AND SHAFT
2 – BODY
3 – DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 – COTTER PIN
5 – RETAINER CAP
6 – SPRING
7 – RELIEF VALVE
8 – LARGE CHAMFERED EDGE
9 – BOLT
10 – COVER
11 – OUTER ROTOR

5.9L ENGINE

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REMOVAL AND INSTALLATION (Continued)

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