Dodge Dakota (R1). Manual - part 497

ing rod oil slinger slot faces the front of the engine
(Fig. 76).

(6) Wipe cylinder bore clean and lubricate with

engine oil.

(7) Rotate crankshaft until connecting rod journal

is on the center of cylinder bore. Insert rod and pis-
ton into cylinder bore and carefully position connect-
ing rod guides over crankshaft journal.

(8) Tap piston down in cylinder bore using a ham-

mer handle. While at the same time, guide connect-
ing rod into position on rod journal.

CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.

(9) Lubricate rod bolts and bearing surfaces with

engine oil. Install connecting rod cap and bearing.
Tighten bolts to 27 N·m (20 ft. lbs.) plus 90°.

(10) Install the following components:
• Cylinder head(s). (Refer to 9 - ENGINE/CYLIN-

DER HEAD - INSTALLATION).

• Timing chain and cover. (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).

• Cylinder head covers (Refer to 9 - ENGINE/

CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).

• Oil pan and gasket/windage tray. (Refer to 9 -

ENGINE/LUBRICATION/OIL

PAN

INSTALLA-

TION).

(11) Fill crankcase with proper engine oil to cor-

rect level.

(12) Connect negative cable to battery.

PISTON RINGS

STANDARD PROCEDURE - PISTON RING
FITTING

Before reinstalling used rings or installing new

rings, the ring clearances must be checked.

(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

(Fig. 77). 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 (Fig.

78)make sure the feeler gauge fits snugly between
the ring land and the ring. Replace any ring not
within specification.

Fig. 76 Piston and Connecting Rod Orientation

1 - MAJOR THRUST SIDE OF PISTON
2 - OIL SLINGER SLOT

Fig. 77 Ring End Gap Measurement - Typical

1 - FEELER GAUGE

9 - 176

ENGINE 4.7L

PISTON & CONNECTING ROD (Continued)

(6) Rotate the ring around the piston, the ring

must rotate in the groove with out binding.

PISTON RING SPECIFICATION CHART

Ring Position

Groove

Maximum

Clearance

Upper Ring

.051-.094mm

0.11mm

(0.0020- .0037 in.)

(0.004 in.)

Intermediate

Ring

0.04-0.08mm

0.10mm

(0.0016-0.0031 in.)

(0.004 in.)

Oil Control

Ring

.019-.229mm

.25mm

(Steel Rails)

(.0007-.0090 in.)

(0.010 in.)

Ring Position

Ring Gap

Wear Limit

Upper Ring

0.23-0.39mm

0.43mm

(0.009-0.015 in.)

(0.0017 in.)

Intermediate

Ring

0.40-0.66mm

0.74mm

(0.015-0.026 in.)

(0.029 in.)

Oil Control

Ring

0.028-0.79mm

1.55mm

(Steel Rail)

(0.011- 0.031 in.)

(0.061 in.)

(7) The No. 1 and No. 2 piston rings have a differ-

ent 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.

• Upper oil ring side rail.

• Lower 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 (Fig. 79) 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 (Fig. 80).

(11) Install No. 1 upper piston ring using a piston

ring installer (Fig. 80).

(12) Position piston ring end gaps as shown in

(Fig. 81). It is important that expander ring gap is at
least 45° from the side rail gaps, but not on the pis-
ton pin center or on the thrust direction.

VIBRATION DAMPER

REMOVAL

(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

REMOVAL).

(3) Drain cooling system (Refer to 7 - COOLING -

STANDARD PROCEDURE).

Fig. 78 Measuring Piston Ring Side Clearance

1 - FEELER GAUGE

Fig. 79 Side Rail—Installation

1 - SIDE RAIL END

ENGINE 4.7L

9 - 177

PISTON RINGS (Continued)

(4) Remove radiator upper hose.
(5) Remove upper fan shroud.
(6) Using Special Tools 6958 Spanner with Adapter

Pins 8346, loosen fan and viscous assembly from
water pump (Fig. 82).

(7) Remove fan and viscous assembly.
(8) Disconnect electrical connector for fan mounted

inside radiator shroud.

NOTE: Transmission cooler line snaps into shroud
lower right hand corner.

(9) Remove crankshaft damper bolt.
(10) Remove damper using Special Tools 8513

Insert and 1026 Three Jaw Puller (Fig. 83).

Fig. 80 Upper and Intermediate Rings—Installation

Fig. 81 Piston Ring End Gap Position

1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP

Fig. 82 Fan Assembly—Removal/Installation

1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2 - FAN

Fig. 83 Crankshaft Damper—Removal

1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026

9 - 178

ENGINE 4.7L

VIBRATION DAMPER (Continued)

INSTALLATION

CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512–A, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.

(1) Align crankshaft damper slot with key in

crankshaft. Slide damper onto crankshaft slightly.

CAUTION: Special Tool 8512–A, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.

(2) Assemble Special Tool 8512–A as follows, The

nut is threaded onto the shaft first. Then the roller
bearing is placed onto the threaded rod (The hard-
ened bearing surface of the bearing MUSTface the
nut). Then the hardened washer slides onto the
threaded rod (Fig. 84). Once assembled coat the
threaded rod’s threads with Mopar

t Nickel Anti-

Seize or (Loctite No. 771).

(3) Using Special Tool 8512–A, press damper onto

crankshaft (Fig. 85).

(4) Install then tighten crankshaft damper bolt to

175 N·m (130 ft. lbs.).

(5) Install fan blade assembly (Refer to 7 - COOL-

ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
INSTALLATION).

(6) Install radiator upper shroud and tighten fas-

teners to 11 N·m (95 in. lbs.).

(7) Connect electrical connector for shroud fan.
(8) Install radiator upper hose.
(9) Install accessory drive belt (Refer to 7 - COOL-

ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).

(10) Refill cooling system (Refer to 7 - COOLING -

STANDARD PROCEDURE).

(11) Connect negative cable to battery.

STRUCTURAL COVER

DESCRIPTION

The structural dust cover is made of die cast alu-

minum and joins the lower half of the transmission
bell housing to the engine bedplate.

OPERATION

The structural cover provides additional power-

train stiffness and reduces noise and vibration.

REMOVAL

(1) Raise vehicle on hoist.
(2) Remove the left hand exhaust pipe from

exhaust manifold.

(3) Loosen the right hand exhaust manifold-to-ex-

haust pipe retaining bolts.

(4) Remove the eight bolts retaining structural

cover (Fig. 86) in the sequence shown.

(5) Pivot the exhaust pipe downward and remove

the structural cover.

Fig. 84 Proper Assembly Method for Special Tool

8512–A

1 - BEARING
2 - NUT
3 - THREADED ROD
4 - BEARING HARDENED SURFACE (FACING NUT)
5 - HARDENED WASHER

Fig. 85 Crankshaft Damper Installation

1 - SPECIAL TOOL 8512

ENGINE 4.7L

9 - 179

VIBRATION DAMPER (Continued)

Content .. 495 496 497 498 ..