Dodge Dakota (R1). Manual — part 506
ENGINE 5.9L
TABLE OF CONTENTS
page
page
ENGINE 5.9L
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 221
AIR CLEANER ELEMENT
CYLINDER HEAD
CYLINDER HEAD GASKET FAILURE . . . . . . . 231
CYLINDER HEAD COVER(S)
INTAKE/EXHAUST VALVES & SEATS
VALVES, GUIDES AND SPRINGS . . . . . . . . . . 233
ROCKER ARM / ADJUSTER ASSEMBLY
ENGINE BLOCK
CAMSHAFT & BEARINGS (IN BLOCK)
CONNECTING ROD BEARINGS
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 239
CONNECTING ROD BEARING FITTING . . . . . 239
CRANKSHAFT
CRANKSHAFT MAIN BEARINGS
CRANKSHAFT MAIN BEARING FITTING . . . . 241
CRANKSHAFT OIL SEAL - FRONT
CRANKSHAFT OIL SEAL - REAR
REAR SEAL AREA LEAKS . . . . . . . . . . . . . . . 244
DISTRIBUTOR BUSHING
HYDRAULIC LIFTERS
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 247
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . 247
PISTON & CONNECTING ROD
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . 249
9 - 212
ENGINE 5.9L
AN
PISTON RINGS
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 250
PISTON RING FITTING. . . . . . . . . . . . . . . . . . 250
VIBRATION DAMPER
FRONT MOUNT
REAR MOUNT
LUBRICATION
OIL
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 258
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 258
OIL FILTER
OIL PAN
OIL PUMP
EXHAUST MANIFOLD
INTAKE MANIFOLD
INTAKE MANIFOLD LEAKAGE . . . . . . . . . . . . 265
TIMING BELT / CHAIN COVER(S)
TIMING BELT/CHAIN AND SPROCKETS
ENGINE 5.9L
DESCRIPTION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type
lightweight,
single
cam,
overhead
valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
The engine lubrication system consists of a rotor
type oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1).
The engine serial number is stamped into a
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).
DIAGNOSIS AND TESTING—ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING - Preformance) or (Refer to 9 - ENGINE - DIAG-
NOSIS AND TESTING - Mechanical). Refer to 14 -
FUEL SYSTEM for fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
Fig. 1 Firing Order
AN
ENGINE 5.9L
9 - 213
• Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING)
• Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
• Cylinder Head Gasket Failure Diagnosis (Refer
to 9 - ENGINE/CYLINDER HEAD - DIAGNOSIS
AND TESTING)
• Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
DIAGNOSIS AND TESTING)
• Lash Adjuster (Tappet) Noise Diagnosis (Refer to
9 - ENGINE/ENGINE BLOCK/HYDRAULIC LIFT-
ERS (CAM IN BLOCK) - DIAGNOSIS AND TEST-
ING)
• Engine Oil Leak Inspection (Refer to 9 -
ENGINE/LUBRICATION - DIAGNOSIS AND TEST-
ING)
DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - PERFORMANCE
PERFORMANCE DIAGNOSIS CHART—GASOLINE ENGINES
CONDITION
POSSIBLE CAUSES
CORRECTION
ENGINE WILL NOT CRANK
1. Weak or dead battery
1. Charge/Replace Battery. (Refer to
8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD
PROCEDURE). Check charging
system. (Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING).
2. Corroded or loose battery
connections
2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s)
3. Check starting system. (Refer to
8 - ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Seized accessory drive
component
4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace seized
component.
5. Engine internal mechanical
failure or hydro-static lock
5. Refer to (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Fig. 2 Engine Identification Number
9 - 214
ENGINE 5.9L
AN
ENGINE 5.9L (Continued)
CONDITION
POSSIBLE CAUSES
CORRECTION
ENGINE CRANKS BUT WILL NOT
START
1. No spark
1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- DESCRIPTION)
2. No fuel
2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s)
and driver circuits. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/
FUEL PUMP - DIAGNOSIS AND
TESTING).
3. Low or no engine compression
3. Perform cylinder compression
pressure test. (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING).
ENGINE LOSS OF POWER
1. Worn or burned distributor rotor
1. Install new distributor rotor
2. Worn distributor shaft
2. Remove and repair distributor
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/
DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark
plugs
3. Clean plugs and set gap. (Refer
to 8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG -
CLEANING).
4. Dirt or water in fuel system
4. Clean system and replace fuel
filter
5. Faulty fuel pump
5. Install new fuel pump
6. Incorrect valve timing
6. Correct valve timing
7. Blown cylinder head gasket
7. Install new cylinder head gasket
8. Low compression
8. Test cylinder compression (Refer
to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9. Burned, warped, or pitted valves
9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust
system
10. Install new parts as necessary
11. Faulty ignition cables
11. Replace any cracked or shorted
cables
12. Faulty ignition coil
12. Test and replace, as necessary
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
ENGINE STALLS OR ROUGH IDLE
1. Carbon build-up on throttle plate
1. Remove throttle body and
de-carbon. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/
THROTTLE BODY - REMOVAL).
2. Engine idle speed too low
2. Check Idle Air Control circuit.
(Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/IDLE AIR CONTROL
MOTOR - DESCRIPTION)
AN
ENGINE 5.9L
9 - 215
ENGINE 5.9L (Continued)
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