Dodge Dakota (R1). Manual - part 535

machined pad located on the left, front corner of the
cylinder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 2).

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 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).

Fig. 1 Firing Order

Fig. 2 Engine Identification Number

ENGINE 5.2L INTERNATIONAL

9a - 59

(2) Disconnect the battery negative cable.
(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 plugs from the
engine.

CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.

(5) With all spark plugs removed, rotate the crank-

shaft using a breaker bar and socket.

(6) Identify the fluid in the cylinders (i.e. coolant,

fuel, oil, etc.).

(7) Make 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 engine oil into the cylinders to lubricate

the walls. This will prevent damage on restart.

(10) Install new spark plugs.
(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.

(15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.

STANDARD PROCEDURE - ENGINE
PERFORMANCE

It is important that the vehicle is operating to its

optimum performance level to maintain fuel economy
and the lowest emission levels. If vehicle is not oper-
ating to these standards, refer to Engine Diagnosis.
The following procedures can assist in achieving the
proper engine diagnosis.

(1) Test cranking amperage draw. (Refer to 8 -

ELECTRICAL/BATTERY

SYSTEM/BATTERY

STANDARD PROCEDURE), Cold Cranking Test.

(2) Check intake manifold bolt torque.
(3) Perform cylinder compression test. (Refer to 9 -

ENGINE - DIAGNOSIS AND TESTING), Cylinder
Compression Pressure Test.

(4) Clean or replace spark plugs as necessary and

adjust gap as specified, (Refer to 8 - ELECTRICAL/
IGNITION CONTROL - SPECIFICATIONS). Tighten
to specifications.

(5) Test resistance of spark plug cables. (Refer to 8

ELECTRICAL/IGNITION

CONTROL/SPARK

PLUG CABLE - DIAGNOSIS AND TESTING), Spark
Plug Cables.

(6) Inspect the primary wires. Test coil output volt-

age and primary resistance. Replace parts as neces-
sary.

(Refer

ELECTRICAL/IGNITION

CONTROL - SPECIFICATIONS).

(7) Test fuel pump for pressure. (Refer to 14 -

FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS).

(8) The air filter elements should be replaced as

specified in Lubrication and Maintenance, (Refer to
LUBRICATION

MAINTENANCE/MAINTE-

NANCE SCHEDULES - DESCRIPTION).

(9) Inspect crankcase ventilation system as out

lined in Lubrication and Maintenance (Refer to
LUBRICATION

MAINTENANCE/MAINTE-

NANCE SCHEDULES - DESCRIPTION). For emis-
sion controls, (Refer to 25 - EMISSIONS CONTROL -
DESCRIPTION) for service procedures.

(10) Road test vehicle as a final test.

STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS

There are several places where form-in-place gas-

kets are used on the engine. DO NOT use form-in-
place gasket material unless specified. Care
must be taken when applying form-in-place gaskets.
Bead size, continuity and location are of great impor-
tance. Too thin a bead can result in leakage while too
much can result in spill-over. A continuous bead of
the proper width is essential to obtain a leak-free
joint.

Two types of form-in-place gasket materials are

used in the engine area (Mopar Silicone Rubber
Adhesive Sealant and Mopar Gasket Maker). Each
have different properties and cannot be used inter-
changeably.

MOPAR SILICONE RUBBER ADHESIVE SEALANT

Mopar Silicone Rubber Adhesive Sealant, normally

black in color, is available in 3 ounce tubes. Moisture
in the air causes the sealant material to cure. This
material is normally used on flexible metal flanges.
It has a shelf life of a year and will not properly cure
if over aged. Always inspect the package for the expi-
ration date before use.

MOPAR GASKET MAKER

Mopar Gasket Maker, normally red in color, is

available in 6 cc tubes. This anaerobic type gasket
material cures in the absence of air when squeezed
between smooth machined metallic surfaces. It will
not cure if left in the uncovered tube. DO NOT use
on flexible metal flanges.

SURFACE PREPARATION

Parts assembled with form-in-place gaskets may be

disassembled

without

unusual

effort.

some

9a - 60

ENGINE 5.2L INTERNATIONAL

ENGINE 5.2L INTERNATIONAL (Continued)

instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.

Scrape or wire brush all gasket surfaces to remove

all loose material. Inspect stamped parts to ensure
gasket rails are flat. Flatten rails with a hammer on
a flat plate, if required. Gasket surfaces must be free
of oil and dirt. Make sure the old gasket material is
removed from blind attaching holes.

GASKET APPLICATION

Assembling parts using a form-in-place gasket

requires care.

Mopar Silicone Rubber Adhesive Sealant should be

applied in a continuous bead approximately 3 mm
(0.12 inch) in diameter. All mounting holes must be
circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4
inch) drop is placed in the center of the gasket con-
tact 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 use of a locating dowel is recom-
mended during assembly to prevent smearing the
material off location.

Mopar Gasket Maker should be applied sparingly

to one gasket surface. The sealant diameter should
be 1.00 mm (0.04 inch) or less. Be certain the mate-
rial 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 the material off location.

STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS

CAUTION: Be sure that the tapped holes maintain
the original center line.

Damaged or worn threads can be repaired. Essen-

tially, 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 ASSEMBLY

(1) Scribe hood hinge outlines on hood. Remove the

hood.

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

ENGINE - STANDARD PROCEDURE).

(4) Remove the air cleaner.

(5) Disconnect the radiator and heater hoses.

Remove radiator (Refer to 7 - COOLING/ENGINE/
RADIATOR - REMOVAL).

(6) Set fan shroud aside.
(7) Disconnect the vacuum supply lines from the

intake manifold.

(8) Remove the distributor cap and wires.
(9) Disconnect the accelerator linkage.
(10) Remove throttle body.
(11) Perform the Fuel System Pressure release

procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).

(12) Disconnect the fuel supply line.
(13) Disconnect the starter wires.
(14) Disconnect the oil pressure sending unit wire.
(15) Discharge the air conditioning system, if

equipped(Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/REFRIGERANT

STAN-

DARD PROCEDURE).

(16) Disconnect the air conditioning hoses.
(17) Disconnect

the

power

steering

hoses,

equipped.

(18) Remove starter motor (Refer to 8 - ELECTRI-

CAL/STARTING/STARTER MOTOR - REMOVAL).

(19) Remove the generator (Refer to 8 - ELECTRI-

CAL/CHARGING/GENERATOR - REMOVAL).

(20) Raise and support the vehicle on a hoist.
(21) Disconnect exhaust pipe at manifold.
(22) Refer to Group 21, Transmissions for trans-

mission removal.

CAUTION: DO NOT lift the engine by the intake
manifold.

(23) Install an engine lifting fixture.
(24) The engine and front driving axle (engine/ax-

le/transmission) are connected through insulators
and support brackets. Separate the engine as follows:

• LEFT SIDE—Remove 2 bolts attaching (engine/

pinion nose/transmission) bracket to transmission
bell housing. Remove 2 bracket to pinion nose adap-
tor bolts. Separate engine from insulator by removing
upper nut washer assembly and bolt from engine
support bracket.

• RIGHT SIDE—Remove 2 bracket to axle (dis-

connect housing) bolts and a bracket to bell housing
bolt. Separate engine from insulator by removing
upper nut washer assembly and bolt from engine
support bracket.

(25) Lower the vehicle.
(26) Install engine assembly on engine repair

stand.

INSTALLATION - ENGINE ASSEMBLY

(1) Remove engine from the repair stand and posi-

tion in the engine compartment.

(2) Install an engine support fixture.

ENGINE 5.2L INTERNATIONAL

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ENGINE 5.2L INTERNATIONAL (Continued)

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