2009 Chrysler Aspen Service & Repair Manual

2007 ENGINE 4.7L - Service Information - Aspen & Durango DIAGNOSIS AND TESTING CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Disable the fuel system. 4. Remove the ASD relay. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. 7. Refer to SPECIFICATIONS . CYLINDER COMBUSTION PRESSURE LEAKAGE The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: Exhaust and intake valve leaks (improper seating). Leaks between adjacent cylinders or into water jacket. Any causes for combustion/compression pressure loss. 1. Check the coolant level and fill as required. DO NOT install the radiator cap. 2. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF. 3. Remove the spark plugs. 4. Remove the oil filler cap. 5. Remove the air cleaner hose. 6. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum and 552 kPa (80 psi) recommended. 7. Perform the test procedures on each cylinder according to the tester manufacturer's instructions. Set piston of cylinder to be tested at TDC compression. While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the radiator coolant. 2007 Dodge Durango 2007 ENGINE 4.7L - Service Information - Aspen & Durango 2007 Dodge Durango 2007 ENGINE 4.7L - Service Information - Aspen & Durango FIXYOURCAR2008@AOL.COM

All gauge pressure indications should be equal, with no more than 25% leakage. FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder. Refer to the following CYLINDER COMBUSTION PRESSURE LEAKAGE CHART. MECHANICAL CONDITION POSSIBLE CAUSE CORRECTION AIR ESCAPES THROUGH THROTTLE BODY Intake valve bent, burnt, or not seated properly Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary. AIR ESCAPES THROUGH TAILPIPE Exhaust valve bent, burnt, or not seated properly Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary. AIR ESCAPES THROUGH RADIATOR Head gasket leaking or cracked cylinder head or block Remove cylinder head and inspect. Replace defective part MORE THAN 50% LEAKAGE FROM ADJACENT CYLINDERS Head gasket leaking or crack in cylinder head or block between adjacent cylinders Remove cylinder head and inspect. Replace gasket, head, or block as necessary MORE THAN 25% LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY Stuck or broken piston rings; cracked piston; worn rings and/or cylinder wall Inspect for broken rings or piston. Measure ring gap and cylinder diameter, taper and out-of-round. Replace defective part as necessary CONDITION POSSIBLE CAUSES CORRECTIONS NOISY VALVES 1. High or low oil level in crankcase. 1. Refer to SPECIFICATIONS . 2. Thin or diluted oil. 2. Change oil and filter. 3. Low oil pressure. 3. Check oil pump, if OK, check rod and main bearings for excessive wear. 4. Dirt in lash adjusters. 4. Replace as necessary. 5. Worn rocker arms. 5. Replace as necessary. 6. Worn lash adjusters 6. Replace as necessary. 7. Worn valve guides. 7. Refer to STANDARD PROCEDURE . 8. Excessive runout of valve seats on valve faces. 8. Refer to STANDARD PROCEDURE . CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Refer to SPECIFICATIONS . 2. Low oil pressure. 2. Check oil pump, if OK, check rod 2007 Dodge Durango 2007 ENGINE 4.7L - Service Information - Aspen & Durango FIXYOURCAR2008@AOL.COM

INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance. These malfunctions may be classified as either performance (e.g, engine idles rough and stalls) or mechanical (e.g, a strange noise). Refer to PERFORMANCE and refer to MECHANICAL for possible causes and corrections of malfunctions. Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the following diagnosis: Cylinder Compression Pressure Test. Refer to CYLINDER COMPRESSION PRESSURE . Cylinder Combustion Pressure Leakage Test. Refer to CYLINDER COMBUSTION PRESSURE LEAKAGE . Engine Cylinder Head Gasket Failure Diagnosis. Refer to CYLINDER HEAD GASKET . Intake Manifold Leakage Diagnosis. Refer to INTAKE MANIFOLD LEAKAGE . PERFORMANCE and main bearings for excessive wear. 3. Thin or diluted oil. 3. Change oil and filter. 4. Excessive bearing clearance. 4. Replace as necessary. 5. Connecting rod journal out-of- round. 5. Service or replace crankshaft. 6. Misaligned connecting rods. 6. Replace bent connecting rods. MAIN BEARING NOISE 1. Insufficient oil supply. 1. Refer to SPECIFICATIONS . 2. Low oil pressure. 2. Check oil pump, if OK, check rod and main bearings for excessive wear. 3. Thin or diluted oil. 3. Change oil and filter. 4. Excessive bearing clearance. 4. Replace as necessary. 5. Excessive end play. 5. Check thrust washers for wear. 6. Crankshaft journal out-of round. 6. Service or replace crankshaft. 7. Loose flywheel or torque converter. 7. Tighten to correct torque CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary. 2. Corroded or loose battery 2. Clean and tighten battery 2007 Dodge Durango 2007 ENGINE 4.7L - Service Information - Aspen & Durango FIXYOURCAR2008@AOL.COM

connections. connections. Apply a coat of light mineral grease to the terminals. 3. Faulty starter. 3. Refer to DIAGNOSIS AND TESTING . 4. Faulty coil or control unit. 4. Refer to REMOVAL . 5. Incorrect spark plug gap. 1. Correct as necessary. 6. Dirt or water in fuel system. 6. Clean system and replace fuel filter. 7. Faulty fuel pump, relay or wiring. 7. Repair or replace as necessary. ENGINE STALLS OR ROUGH IDLE 1. Dirty or incorrectly gapped spark plugs. 1. Correct as necessary. 2. Idle mixture too lean or too rich. 2. Refer to appropriate Engine ELECTRICAL DIAGNOSTICS article. . 3. Vacuum leak. 3. Inspect intake manifold and vacuum hoses, repair or replace as necessary. 4. Faulty coil. 4. Refer to REMOVAL . 5. Incorrect engine timing. 5. Refer to STANDARD PROCEDURE . ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark plugs. 1. Correct as necessary. 2. Dirt or water in fuel system. 2. Clean system and replace fuel filter. 3. Faulty fuel pump. 3. Refer to FUEL SYSTEM . 4. Blown cylinder head gasket. 4. Replace cylinder head gasket. 5. Low compression. 5. Refer to CYLINDER COMPRESSION PRESSURE . 6. Burned, warped or pitted valves. 6. Replace as necessary. 7. Plugged or restricted exhaust system. 7. Inspect and replace as necessary. 8. Faulty coil. 8. Refer to REMOVAL . ENGINE MISSES ON ACCELERATION 1. Spark plugs dirty or incorrectly gapped. 1. Correct as necessary. 2. Dirt in fuel system. 2. Clean fuel system. 3. Burned, warped or pitted valves. 3. Replace as necessary. 4. Faulty coil. 4. Refer to REMOVAL . ENGINE MISSES AT HIGH SPEED 1. Spark plugs dirty or incorrectly gapped. 1. Correct as necessary. 2. Faulty coil. 2. Refer to REMOVAL . 3. Dirt or water in fuel system. 3. Clean system and replace fuel 2007 Dodge Durango 2007 ENGINE 4.7L - Service Information - Aspen & Durango FIXYOURCAR2008@AOL.COM

ENGINE DIAGNOSIS - LUBRICATION filter. CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. Misaligned or damaged. 1. Replace as necessary. (a) Loose fasteners, broken or porous metal parts. (a) Tighten fasteners, Repair or replace metal parts. 2. Crankshaft rear seal 2. Replace as necessary. Refer to REMOVAL . 3. Crankshaft seal flange. Scratched, nicked or grooved. 3. Polish or replace crankshaft. 4. Oil pan flange cracked. 4. Replace oil pan. Refer to REMOVAL . 5. Timing chain cover seal, damaged or misaligned. 5. Replace seal. Refer to REMOVAL . 6. Scratched or damaged vibration damper hub. 6. Polish or replace damper. OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level. 2. Faulty oil pressure sending unit. 2. Replace sending unit. Refer to REMOVAL . 3. Low oil pressure. 3. Check oil pump and bearing clearance. 4. Clogged oil filter. 4. Replace oil filter. Refer to REMOVAL . 5. Worn oil pump. 5. Replace oil pump. Refer to REMOVAL . 6. Thin or diluted oil. 6. Change oil and filter. 7. Excessive bearing clearance. 7. Replace as necessary. 8. Oil pump relief valve stuck. 8. Replace oil pump. Refer to REMOVAL . 9. Oil pick up tube loose, damaged or clogged. 9. Replace as necessary. OIL PUMPING AT RINGS; SPARK PLUGS FOULING 1. Worn or damaged rings. 1. Hone cylinder bores and replace rings. 2. Carbon in oil ring slots. 2. Replace rings. Refer to STANDARD PROCEDURE . 3. Incorrect ring size installed. 3. Replace rings. Refer to STANDARD PROCEDURE . 4. Worn valve guides. 4. Ream guides and replace valves. Refer to STANDARD PROCEDURE . 5. Leaking valve guide seals. 5. Replace valve guide seals. 2007 Dodge Durango 2007 ENGINE 4.7L - Service Information - Aspen & Durango FIXYOURCAR2008@AOL.COM

STANDARD PROCEDURE FORM-IN-PLACE GASKETS AND SEALERS There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket. There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other. MOPAR® ENGINE RTV GEN II Mopar® Engine RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPAR® ATF RTV Mopar® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPAR® GASKET MAKER Mopar® Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges. MOPAR® GASKET SEALANT Mopar® Gasket Sealant is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator. FORM-IN-PLACE GASKET AND SEALER APPLICATION Assembling parts using a form-in-place gasket requires care but it's easier than using precut gaskets. 2007 Dodge Durango 2007 ENGINE 4.7L - Service Information - Aspen & Durango FIXYOURCAR2008@AOL.COM

Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location. Mopar® Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location. Mopar® Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets. REPAIR DAMAGED OR WORN THREADS Damaged or worn threads can be repaired. Essentially, this repair consists of: Drilling out worn or damaged threads. Tapping the hole with a special Heli-Coil Tap, or equivalent. Installing an insert into the tapped hole to bring the hole back to its original thread size. REMOVAL ENGINE CAUTION: Be sure that the tapped holes maintain the original center line. 2007 Dodge Durango 2007 ENGINE 4.7L - Service Information - Aspen & Durango FIXYOURCAR2008@AOL.COM

Fig. 1: Cowl Grille Courtesy of CHRYSLER LLC 1. Remove the cowl grille (4), and the cross-bar beam. Refer to REMOVAL . 2. Release fuel rail pressure. Refer to STANDARD PROCEDURE , then disconnect the fuel supply quick connect fitting at the fuel rail. Refer to STANDARD PROCEDURE . 2007 Dodge Durango 2007 ENGINE 4.7L - Service Information - Aspen & Durango FIXYOURCAR2008@AOL.COM

Fig. 2: Belt Routing 3.7L / 4.7L Courtesy of CHRYSLER LLC 3. Disconnect the battery negative cable. 4. Remove air cleaner assembly. 5. Remove fan shroud with viscous fan assembly. 6. Remove drive belt (2). 2007 Dodge Durango 2007 ENGINE 4.7L - Service Information - Aspen & Durango FIXYOURCAR2008@AOL.COM

Fig. 3: Removing/Installing A/C Compressor Courtesy of CHRYSLER LLC 7. Remove A/C compressor (2) and secure away from engine. 2007 Dodge Durango 2007 ENGINE 4.7L - Service Information - Aspen & Durango FIXYOURCAR2008@AOL.COM

2009 Chrysler Aspen Service & Repair Manual

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