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Dodge Dakota (R1). Manual - part 520

TIMING BELT / CHAIN
COVER(S)

REMOVAL

(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (Refer to 7 - COOLING -

STANDARD PROCEDURE).

(3) Remove the serpentine belt (Refer to 7 - COOL-

ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).

(4) Remove water pump (Refer to 7 - COOLING/

ENGINE/WATER PUMP - REMOVAL).

(5) Remove power steering pump (refer to Steer-

ing).

(6) Remove

vibration

damper

(Refer

ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).

(7) Remove fuel lines (refer to Fuel System).
(8) Loosen oil pan bolts and remove the front bolt

at each side.

(9) Remove the cover bolts.
(10) Remove chain case cover and gasket using

extreme caution to avoid damaging oil pan gasket.

(11) 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 surface of cover (Fig. 80).

INSTALLATION

(1) Be sure mating surfaces of chain case cover

and cylinder block are clean and free from burrs.

(2) The water pump mounting surface must be

cleaned.

(3) Using a new cover gasket, carefully install

chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar

t GEN II Silicone Rub-

ber Adhesive Sealant, or equivalent, at the joint
between timing chain cover gasket and the oil pan
gasket. Finger tighten the timing chain cover bolts at
this time.

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

Front Oil Seal Installation Tool 6635 (Fig. 81). Seat
the oil seal in the groove of the tool.

(5) Position the seal and tool onto the crankshaft

(Fig. 82).

(6) Tighten the 4 lower chain case cover bolts to

13N·m (10 ft.lbs.) to prevent the cover from tipping
during seal installation.

(7) Using the vibration damper bolt, tighten the

bolt to draw the seal into position on the crankshaft
(Fig. 83).

Fig. 80 Removal of Front Crankshaft Oil Seal

Fig. 81 Placing Oil Seal on Installation Tool 6635

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

Fig. 82 Position Tool and Seal onto Crankshaft

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

9 - 268

ENGINE 5.9L

(8) Loosen the 4 bolts tightened in step 4 to allow

realignment of front cover assembly.

(9) Tighten chain case cover bolts to 41 N·m (30 ft.

lbs.) torque. Tighten oil pan bolts to 24 N·m (215 in.
lbs.) torque.

(10) Remove the vibration damper bolt and seal

installation tool.

(11) Install

vibration

damper

(Refer

ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).

(12) Install water pump (Refer to 7 - COOLING/

ENGINE/WATER PUMP - INSTALLATION).

(13) Install power steering pump (refer to Steer-

ing).

(14) Install the serpentine belt (Refer to 7 - COOL-

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

(15) Install the cooling system fan (Refer to 7 -

COOLING/ENGINE/FAN

DRIVE

VISCOUS

CLUTCH - INSTALLATION).

(16) Position the fan shroud and install the bolts.

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

(17) Fill cooling system (Refer to 7 - COOLING -

STANDARD PROCEDURE).

(18) Connect the negative cable to the battery.

TIMING BELT/CHAIN AND
SPROCKETS

REMOVAL

(1) Disconnect battery negative cable.
(2) Remove Timing Chain Cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).

(3) Re-install the vibration damper bolt finger

tight. Using a suitable socket and breaker bar, rotate
the crankshaft to align timing marks as shown in
(Fig. 84).

(4) Remove camshaft sprocket attaching bolt and

remove timing chain with crankshaft and camshaft
sprockets.

Fig. 83 Installing Oil Seal

1 - SPECIAL TOOL 6635
2 - TIMING CHAIN COVER

Fig. 84 Alignment of Timing Marks

1 - TIMING MARKS

ENGINE 5.9L

9 - 269

TIMING BELT / CHAIN COVER(S) (Continued)

INSTALLATION

(1) Place both camshaft sprocket and crankshaft

sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.

(2) Place timing chain around both sprockets.
(3) Turn crankshaft and camshaft to line up with

keyway location in crankshaft sprocket and in cam-
shaft sprocket.

(4) Lift sprockets and chain (keep sprockets tight

against the chain in position as described).

(5) Slide both sprockets evenly over their respec-

tive shafts and use a straightedge to check alignment
of timing marks (Fig. 85).

(6) Install the camshaft bolt. Tighten the bolt to 68

N·m (50 ft. lbs.) torque.

(7) Check camshaft end play. The end play should

be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.

(8) Install the timing chain cover (Refer to 9 -

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

Fig. 85 Alignment of Timing Marks

1 - TIMING MARKS

9 - 270

ENGINE 5.9L

TIMING BELT/CHAIN AND SPROCKETS (Continued)

ENGINE 2.5L VM DIESEL INTERNATIONAL

TABLE OF CONTENTS

page

ENGINE 2.5L VM DIESEL INTERNATIONAL . . . . . . 1

ENGINE 5.2L INTERNATIONAL. . . . . . . . . . . . . . . 58