Dodge Dakota (R1). Manual - part 536

(3) Raise and support the vehicle on a hoist.
(4) Install the engine front mounts.
(5) Refer to Group, 21 Transmissions for transmis-

sion installation.

(6) Install the inspection plate.
(7) Remove transmission support.
(8) Install exhaust pipe to manifold.
(9) Lower the vehicle.
(10) Remove engine lifting fixture.
(11) Install the generator (Refer to 8 - ELECTRI-

CAL/CHARGING/GENERATOR - INSTALLATION).

(12) Install starter motor (Refer to 8 - ELECTRI-

CAL/STARTING/STARTER MOTOR - INSTALLA-
TION).

(13) Connect power steering hoses, if equipped.
(14) Connect air conditioning hoses.
(15) Evacuate and charge the air conditioning sys-

tem, if equipped (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/REFRIGERANT

STANDARD PROCEDURE).

(16) Using a new gasket, install throttle body.

Tighten the throttle body bolts to 23 N·m (200 in.
lbs.) torque.

(17) Connect the accelerator linkage.
(18) Connect the starter wires.
(19) Connect the oil pressure sending unit wire.
(20) Install the distributor cap and wiring.
(21) Connect the vacuum supply lines to the

intake manifold.

(22) Connect the fuel supply lines.
(23) Install the radiator (Refer to 7 - COOLING/

ENGINE/RADIATOR - INSTALLATION). Connect
the radiator hoses and heater hoses.

(24) Install fan shroud in position.
(25) Fill cooling system (Refer to 7 - COOLING/

ENGINE - STANDARD PROCEDURE).

(26) Install the air cleaner.
(27) Install the battery.
(28) Warm engine and adjust.
(29) Install hood and line up with the scribe

marks.

(30) Road test vehicle.

SPECIFICATIONS

TORQUE

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Camshaft Sprocket—Bolt

—

Camshaft Thrust Plate—Bolts

—

210

Chain Case Cover—Bolts

—

Connecting Rod Cap—Bolts

—

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Main Bearing Cap—Bolts

115

—

Crankshaft Pulley—Bolts

—

210

Cylinder Head—Bolts

Step 1

—

Step 2

143

105

—

Cylinder Head Cover—Bolts

—

Engine Support Bracket to
Block—Bolts (4WD)

—

Exhaust Manifold to Cylinder
Head—Bolts/Nuts

—

Flywheel—Bolts

—

Front Insulator—Through
bolt/nut

—

Front Insulator to Support
Bracket—

Stud Nut (4WD)

—

Through Bolt/Nut

102

—

Front Insulator to Block—Bolts
(2WD)

—

Generator—Mounting Bolts

—

Intake Manifold—Bolts

Refer to

Procedure

Oil Pan—Bolts

—

215

Oil Pan—Drain Plug

—

Oil Pump—Mounting Bolts

—

Oil Pump Cover—Bolts

—

Rear Insulator to Bracket—
Through Bolt (2WD)

—

Rear Insulator to Crossmember
Support Bracket—Nut (2WD)

—

Rear Insulator to
Crossmember—Nuts (4WD)

—

Rear Insulator to
Transmission—Bolts (4WD)

Rear Insulator Bracket—Bolts
(4WD Automatic)

—

Rear Support Plate to Transfer
Case—Bolts

Rocker Arm—Bolts

—

Spark Plugs

—

Starter Motor—Mounting Bolts

—

Thermostat Housing—Bolts

—

225

Throttle Body—Bolts

—

200

9a - 62

ENGINE 5.2L INTERNATIONAL

ENGINE 5.2L INTERNATIONAL (Continued)

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Torque Converter Drive
Plate—Bolts

—

270

Transfer Case to Insulator
Mounting Plate—Nuts

204

150

—

Transmission Support Bracket—
Bolts (2WD)

—

Vibration Damper—Bolt

183

135

—

Water Pump to Timing Chain
Case Cover—Bolts

—

5.2L ENGINE

ENGINE SPECIFICATIONS

DESCRIPTION

SPECIFICATION

GENERAL SPECIFICATIONS

Engine Type

90° V-8 OHV

Bore and Stroke

99.3 x 84.0 mm

(3.91 x 3.31 in.)

Displacement

5.2L

(318 c.i.)

Compression Ratio

9.1:1

Firing Order

1–8–4–3–6–5–7–2

Lubrication

Pressure Feed—

Full Flow Filtration

Cooling System

Liquid Cooled—

Forced Circulation

Cylinder Block

Cast Iron

Crankshaft

Nodular Iron

Cylinder Head

Cast Iron

Combustion Chambers

Wedge-High Swirl

Valve shrouding

Camshaft

Nodular Cast Iron

Pistons

Aluminum Alloy w/strut

Connecting Rods

Forged Steel

Cylinder Compression

689.5 kPa

Pressure (Min.)

(100 psi)

DESCRIPTION

SPECIFICATION

CAMSHAFT

Bearing Diameter

No. 1

50.800 – 50.825 mm

(2.000 – 2.001 in.)

No. 2

50.394 – 50.419 mm

(1.984 – 1.985 in.)

No. 3

50.013 – 50.038 mm

(1.969 – 1.970 in.)

No. 4

49.606 – 49.632 mm

(1.953 – 1.954 in.)

No. 5

39.688 – 39.713 mm

(1.5625 – 1.5635 in.)

Bearing Journal Diameter

No. 1

50.749 – 50.775 mm

(1.998 – 1.999 in.)

No. 2

50.343 – 50.368 mm

(1.982 – 1.983 in.)

No. 3

49.962 – 49.987 mm

(1.967 – 1.968 in.)

No. 4

49.555 – 49.581 mm

(1.951 – 1.952 in.)

No. 5

39.637 – 39.662 mm

(1.5605 – 1.5615 in.)

Bearing to Journal
Clearance

Standard

0.0254 – 0.0762 mm

(0.001 – 0.003 in.)

Service Limit

0.127 mm

(0.005 in.)

End Play

0.051 – 0.254 mm

(0.002 – 0.010 in.)

CONNECTING RODS

Piston Pin bore Diameter

24.966 – 24.978 mm

(0.9829 – 0.9834 in.)

Side Clearance

0.152 – 0.356 mm

(0.006 – 0.014 in.)

ENGINE 5.2L INTERNATIONAL

9a - 63

ENGINE 5.2L INTERNATIONAL (Continued)

DESCRIPTION

SPECIFICATION

CRANKSHAFT

Rod Journal

Diameter

53.950 – 53.975 mm

(2.124 – 2.125 in.)

Out of Round (Max.)

0.0254 mm

(0.001 in.)

Taper (Max.)

0.0254 mm

(0.001 in.)

Bearing Clearance

0.013 – 0.056 mm

(0.0005 – 0.0022 in.)

Service Limit

0.0762 mm

(0.003 in.)

Main Bearing Journal

Diameter

63.487 – 63.513 mm

(2.4995 – 2.5005in.)

Out of Round (Max.)

0.127 mm

(0.001 in.)

Taper (Max.)

0.0254 mm

(0.001 in.)

Bearing Clearance

(#1 Journal)

0.013 – 0.038 mm

(0.0005 – 0.0015 in.)

(#2-5 Journals)

0.013 – 0.051 mm

(0.0005 – 0.002 in.)

Service Limit

(#1 Journal)

0.0381 mm

(0.0015 in.)

(#2-5 Journals)

0.064 mm

(0.0025 in.)

End Play

0.051 – 0.178 mm

(0.002 – 0.007 in.)

Service Limit

0.254 mm

(0.010 in.)

CYLINDER BLOCK

Cylinder Bore

Diameter

99.308 – 99.371 mm

(3.9098 – 3.9122 in.)

Out of Round (Max.)

0.025 mm

(0.001 in.)

Taper (Max.)

0.025 mm

DESCRIPTION

SPECIFICATION

(0.001 in.)

Oversize Limit

1.016 mm

(0.040 in.)

Lifter Bore Diameter

22.99 – 23.01 mm

(0.9051 – 0.9059 in.)

Distributor Drive Bushing

(Press Fit)

Bushing to Bore

Interference

0.0127 – 0.3556 mm

(0.0005 – 0.0140 in.)

Shaft to Bushing

Clearance

0.0178 – 0.0686 mm

(0.0007 – 0.0027 in.)

CYLINDER HEAD

Valve Seat

Angle

44.25° – 44.75°

Runout (Max.)

0.0762 mm

(0.003 in.)

Width (Finish)

Intake

1.016 – 1.524 mm

(0.040 – 0.060 in.)

Exhaust

1.524 – 2.032 mm

(0.060 – 0.080 in.)

VALVES

Face Angle

43.25° – 43.75°

Head Diameter

Intake

48.666 mm

(1.916 in.)

Exhaust

41.250 mm

(1.624 in.)

Length (Overall)

Intake

124.28 – 125.92 mm

(4.893 – 4.918 in.)

Exhaust

124.64 – 125.27 mm

(4.907 – 4.932 in.)

Lift (@ zero lash)

10.973 mm

(0.432 in.)

Stem Diameter

7.899 – 7.925 mm

(0.311 – 0.312 in.)

9a - 64

ENGINE 5.2L INTERNATIONAL

ENGINE 5.2L INTERNATIONAL (Continued)

DESCRIPTION

SPECIFICATION

Guide Bore

7.950 – 7.976 mm

(0.313 – 0.314 on.)

Stem to Guide Clearance

0.0254 – 0.0762 mm

(0.001 – 0.003 in.)

Service Limit (rocking
method)

0.4318 mm

(0.017 in.)

VALVE SPRINGS

Free Length

49.962 mm

(1.967 in.)

Spring Tension

valve closed

378 N @ 41.66 mm

(85 lbs. @ 1.64 in.)

valve open

890 N @ 30.89 mm

(200 lbs. @ 1.212 in.)

Number of Coils

6.5

Installed Height

41.66 mm

(1.64 in.)

Wire Diameter

4.50 mm

(0.177 in.)

HYDRAULIC TAPPETS

Body Diameter

22.949 – 22.962 mm

(0.9035 – 0.9040 in.)

Clearance (to bore)

0.0279 – 0.0610 mm

(0.0011 – 0.0024 in.)

Dry Lash

1.524 – 5.334 mm

(0.060 – 0.210 in.)

Push Rod Length

175.64 – 176.15 mm

(6.915 – 6.935 in.)

OIL PRESSURE

Curb Idle (Min.*)

41.4 kPa (6 psi)

@ 3000 rpm

207 – 552 kPa

(30 – 80 psi)

Oil Pressure Bypass
Valve

Setting

62 – 103 kPa

(9 – 15 psi)

DESCRIPTION

SPECIFICATION

Switch Actuating
Pressure

34.5 – 48.3 kPa

(5 – 7 psi)

* If oil pressure is zero at curb idle, DO NOT RUN

ENGINE.

OIL PUMP

Clearance over Rotors
(Max.)

0.0381 mm

(0.0015 in.)

Inner Rotor Thickness
(Min.)

20.955 mm

(0.825 in.)

Outer Rotor Clearance
(Max.)

0.3556 mm

(0.014 in.)

Outer Rotor Diameter
(Min.)

62.7126 mm

(2.469 in.)

Outer Rotor Thickness
(Min.)

20.955 mm

(0.825 in.)

Tip Clearance between
Rotors

(Max.)

0.2032 mm

(0.008 in.)

PISTONS

Clearance at Top of Skirt

0.013 – 0.038 mm

(0.0005 – 0.0015 in.)

Land Clearance (Diam.)

0.635 – 1.016 mm

(0.025 – 0.040 in.)

Piston Length

86.360 mm (3.40 in.)

Piston Ring Groove
Depth

Groove #1&2

4.572 – 4.826 mm

(0.180 – 0.190 in.)

Groove #3

3.810 – 4.064 mm

(0.150 – 0.160 in.)

Weight

592.6 – 596.6 grams

(20.90 – 21.04 oz.)

ENGINE 5.2L INTERNATIONAL

9a - 65

ENGINE 5.2L INTERNATIONAL (Continued)

Content .. 534 535 536 537 ..