Dodge Dakota (R1). Manual - part 541

CRANKSHAFT OIL SEAL -
REAR

DESCRIPTION

The crankshaft rear seal is a two piece viton seal.

The crankshaft front seal is a one piece viton seal
with a steel housing. The front seal is located in the
engine front cover. One part of the two piece rear
seal is located in a slot in the number five (5) crank-
shaft main bore, the second part of the two piece seal
is located in the number five (5) main bearing cap.

OPERATION

The crankshaft seals prevent oil from leaking from

around the crankshaft, either from the rear of the
engine or from the engine front cover.

REMOVAL

CRANKSHAFT OIL SEALS - REAR

The service seal is a two piece, viton seal. The

upper seal half can be installed with crankshaft
removed from engine or with crankshaft installed.
When a new upper seal is installed, install a new
lower seal. The lower seal half can only be installed
with the rear main bearing cap removed.

UPPER SEAL - CRANKSHAFT REMOVED

(1) Remove the crankshaft (Refer to 9 - ENGINE/

ENGINE BLOCK/CRANKSHAFT - REMOVAL). Dis-
card the old upper seal.

UPPER SEAL - CRANKSHAFT INSTALLED

(1) Remove the oil pan (Refer to 9 - ENGINE/LU-

BRICATION/OIL PAN - REMOVAL).

(2) Remove the oil pump from the rear main bear-

ing cap (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - REMOVAL).

(3) Remove the rear main bearing cap. Remove

and discard the old lower oil seal.

(4) Carefully remove and discard the old upper oil

seal.

LOWER SEAL

(1) Remove the oil pan (Refer to 9 - ENGINE/LU-

BRICATION/OIL PAN - REMOVAL).

(2) Remove the oil pump from the rear main bear-

ing cap (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - REMOVAL).

(3) Remove the rear main bearing cap and discard

the old lower seal.

INSTALLATION

CRANKSHAFT OIL SEALS - REAR

The service seal is a two piece, viton seal. The

UPPER SEAL - CRANKSHAFT REMOVED

(1) Clean the cylinder block rear cap mating sur-

face. Make sure the seal groove is free of debris.

(2) Lightly oil the new upper seal lips with engine

oil.

(3) Install the new upper rear bearing oil seal with

the white paint facing towards the rear of the engine.

(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine

oil.

(6) Install the new lower rear bearing oil seal into

the bearing cap with the white paint facing towards
the rear of the engine.

(7) Apply 5 mm (0.20 in.) drop of Mopar

t Gasket

Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 29). DO NOT over-apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.

Fig. 29 Sealant

1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS
2 - MOPAR

GASKET MAKER (OR EQUIVALENT)

3 - CAP ALIGNMENT SLOT
4 - REAR MAIN BEARING CAP

9a - 82

ENGINE 5.2L INTERNATIONAL

(8) To align the bearing cap, use cap slot, align-

ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than two times for proper engagement.

(9) Clean and oil all cap bolts. Install all main

bearing caps. Install all cap bolts and alternately
tighten to 115 N·m (85 ft. lbs.) torque.

(10) Install oil pump.
(11) Apply Mopar

t Silicone Rubber Adhesive Seal-

ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 30).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.

(12) Install new front crankshaft oil seal
(13) Immediately install the oil pan.

UPPER SEAL - CRANKSHAFT INSTALLED

(1) Clean the cylinder block mating surfaces before

oil seal installation. Check for burrs at the oil hole on
the cylinder block mating surface to rear cap.

(2) Lightly oil the new upper seal lips with engine

oil. To allow ease of installation of the seal, loosen at
least the two main bearing caps forward of the rear
bearing cap.

(3) Rotate the new upper seal into the cylinder

block, being careful not to shave or cut the outer sur-
face of the seal. To ensure proper installation, use the
installation tool provided with the kit. Install the
new seal with the white paint facing toward the rear
of the engine.

(4) Install the new lower rear bearing oil seal into

the bearing cap with the white paint facing toward
the rear of the engine.

(5) Apply 5 mm (0.20 in.) drop of Mopar

t Gasket

(6) To align the bearing cap, use cap slot, align-

ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than two times for proper engagement.

(7) Install the rear main bearing cap with cleaned

and oiled cap bolts. Alternately tighten ALL cap bolts
to 115 N·m (85 ft. lbs.) torque.

(8) Install oil pump.
(9) Apply Mopar

t Silicone Rubber Adhesive Seal-

(10) Immediately install the oil pan.

LOWER SEAL

(1) Clean the rear main cap mating surfaces

including the oil pan gasket groove.

(2) Carefully install a new upper seal. Refer to

UPPER SEAL - CRANKSHAFT INSTALLED .

(3) Lightly oil the new lower seal lips with engine

oil.

(4) Install a new lower seal in bearing cap with

the white paint facing the rear of engine.

(5) Apply 5 mm (0.20 in.) drop of Mopar

t Gasket

(6) To align the bearing cap, use cap slot, align-

ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than two times for proper engagement.

(7) Install the rear main bearing cap with cleaned

and oiled cap bolts. Alternately tighten the cap bolts
to 115 N·m (85 ft. lbs.) torque.

(8) Install oil pump.
(9) Apply Mopar

t Silicone Rubber Adhesive Seal-

ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing. Apply
enough sealant until a small amount is squeezed out.
Withdraw nozzle and wipe excess sealant off the oil
pan seal groove.

(10) Immediately install the oil pan.

Fig. 30 Apply Sealant to Bearing Cap to Block Joint

1 - MOPAR

GEN II SILICONE RUBBER ADHESIVE SEALANT

NOZZLE TIP
2 - SEALANT APPLIED
3 - CYLINDER BLOCK
4 - REAR MAIN BEARING CAP

ENGINE 5.2L INTERNATIONAL

9a - 83

CRANKSHAFT OIL SEAL - REAR (Continued)

DISTRIBUTOR DRIVE SHAFT
BUSHING

REMOVAL

(1) Remove distributor, (Refer to 8 - ELECTRI-

CAL/IGNITION

CONTROL/DISTRIBUTOR

REMOVAL) for the proper procedure.

(2) Remove the intake manifold. (Refer to 9 -

ENGINE/MANIFOLDS/INTAKE

MANIFOLD

REMOVAL) for correct procedure.

(3) Insert Distributor Drive Shaft Bushing Puller

Tool C-3052 into old bushing and thread down until a
tight fit is obtained (Fig. 31).

(4) Hold puller screw and tighten puller nut until

bushing is removed.

INSTALLATION

(1) Slide new bushing over burnishing end of Dis-

tributor Drive Shaft Bushing Driver/Burnisher Tool
C-3053. Insert the tool and bushing into the bore.

(2) Drive bushing and tool into position, using a

hammer (Fig. 32).

(3) As the burnisher is pulled through the bushing,

the bushing is expanded tight in the block and bur-
nished to correct size (Fig. 33). DO NOT ream this
bushing.

CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
occur.

(4) Install the intake manifold.

DISTRIBUTOR INSTALLATION

NOTE: Before installing the distributor, the oil pump
drive shaft must be aligned to number one cylinder.

(1) Rotate crankshaft until No. 1 cylinder is at top

dead center on the firing stroke.

(2) When in this position, the timing mark of

vibration damper should be under “0” on the timing
indicator.

(3) Install the shaft so that after the gear spirals

into place, it will index with the oil pump shaft. The
slot on top of oil pump shaft should be aligned
toward the left front intake manifold attaching bolt
hole (Fig. 34).

(4) Install distributor. (Refer to 8 - ELECTRICAL/

IGNITION CONTROL/DISTRIBUTOR - INSTALLA-
TION) for the proper procedure.

After the distributor has been installed, its rota-

tional position must be set using the SET SYNC
mode of the DRB scan tool. (Refer to 8 - ELECTRI-
CAL/IGNITION

CONTROL/DISTRIBUTOR

INSTALLATION), for Checking Distributor Position.

Do not attempt to adjust ignition timing by

rotating the distributor. It has no effect on igni-
tion timing. Adjusting distributor position will
affect fuel synchronization only.

Fig. 31 Distributor Driveshaft Bushing Removal

1 - SPECIAL TOOL C-3052
2 - BUSHING

Fig. 32 Distributor Driveshaft Bushing Installation

1 - SPECIAL TOOL C-3053
2 - BUSHING

Fig. 33 Burnishing Distributor Driveshaft Bushing

1 - SPECIAL TOOL C-3053
2 - BUSHING

9a - 84

ENGINE 5.2L INTERNATIONAL

HYDRAULIC TAPPETS

REMOVAL

(1) Remove the air cleaner assembly and air inlet

hose.

(2) Remove cylinder head cover, rocker assembly

and push rods. Identify push rods to ensure installa-
tion in original location.

(3) Remove intake manifold, yoke retainer and

aligning yokes.

(4) Slide Hydraulic Tappet Remover/Installer Tool

C-4129-A through opening in cylinder head and seat
tool firmly in the head of tappet.

(5) Pull tappet out of bore with a twisting motion.

If all tappets are to be removed, identify tappets to
ensure installation in original location.

INSTALLATION

(1) If the tappet or bore in cylinder block is scored,

scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet.

(2) Lubricate tappets.
(3) Install tappets and push rods in their original

positions. Ensure that the oil feed hole in the side of
the tappet body faces up (away from the crankshaft).

(4) Install aligning yokes with ARROW toward

camshaft.

(5) Install yoke retainer. Tighten the bolts to 23

N·m (200 in. lbs.) torque. Install intake manifold.

(6) Install push rods in original positions.
(7) Install rocker arm.
(8) Install cylinder head cover.
(9) Install air cleaner assembly and air inlet hose.
(10) Start and operate engine. Warm up to normal

operating temperature.

CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.

PISTON & CONNECTING ROD

DESCRIPTION

The pistons are made of aluminum and have three

ring grooves, the top two grooves are for the compres-
sion rings and the bottom groove is for the oil control
ring. The connecting rods are forged steel and are
coined prior to heat treat. The piston pins are press
fit.

STANDARD PROCEDURE - PISTON FITTING

Piston and cylinder wall must be clean and dry.

Specified clearance between the piston and the cylin-
der wall is 0.013-0.038 mm (0.0005-0.0015 in.) at
21°C (70°F).

Piston diameter should be measured at the top of

skirt, 90° to piston pin axis. Cylinder bores should be
measured halfway down the cylinder bore and trans-
verse to the engine crankshaft center line.

Pistons and cylinder bores should be measured at

normal room temperature, 21°C (70°F).

Check the pistons for taper and elliptical shape

before they are fitted into the cylinder bore (Fig. 35).

Fig. 34 Position of Oil Pump Shaft Slot

1 - DISTRIBUTOR DRIVE

Fig. 35 Piston Measurements

1 - 49.53 mm
(1.95 IN.)

ENGINE 5.2L INTERNATIONAL

9a - 85

DISTRIBUTOR DRIVE SHAFT BUSHING (Continued)

Content .. 539 540 541 542 ..