Dodge Dakota (R1). Manual — part 546
INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the exhaust manifold, install new studs.
(1) Position the exhaust manifolds on the two
studs located on the cylinder head. Install conical
washers and nuts on these studs (Fig. 70).
(2) Install new bolt and washer assemblies in the
remaining holes (Fig. 70). Start at the center arm
and work outward. Tighten the bolts and nuts to 24
N·m (18 ft. lbs.) torque.
(3) Position three washers, heat shield and nuts on
the right side exhaust manifold. Tighten nuts to 24
N·m (18 ft. lbs.).
(4) Position two washers, heat shield and nuts on
the left side exhaust manifold. Tighten nuts to 24
N·m (18 ft. lbs.).
(5) Raise and support the vehicle.
(6) Assemble the exhaust pipe to the exhaust man-
ifold and secure with bolts, nuts and washers.
Tighten these nuts to 27 N·m (20 ft. lbs.) torque.
(7) Lower the vehicle.
(8) Connect the negative cable to the battery.
VALVE TIMING
STANDARD PROCEDURE - VALVE TIMING
(1) Turn crankshaft until the No.6 exhaust valve is
closing and No.6 intake valve is opening.
(2) Insert a 6.350 mm (1/4 inch) spacer between
rocker arm pad and stem tip of No.1 intake valve.
Allow spring load to bleed tappet down giving in
effect a solid tappet.
(3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as pos-
sible. Zero the indicator.
(4) Rotate the crankshaft clockwise (normal run-
ning direction) until the valve has lifted 0.863 mm
(0.034 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
top dead center. Remove spacer.
CAUTION: DO NOT turn crankshaft any further
clockwise as valve spring might bottom and result
in serious damage.
If reading is not within specified limits:
• Check sprocket index marks.
• Inspect timing chain for wear.
• Check accuracy of DC mark on timing indicator.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE - 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 19 -
STEERING/PUMP - REMOVAL).
Fig. 71 Exhaust Manifold Heat Shield - Right Side
1 - WASHER
2 - NUT AND WASHER
3 - EXHAUST MANIFOLD HEAT SHIELD
Fig. 72 Exhaust Manifold Heat Shield - Left Side
1 - WASHER
2 - NUT AND WASHER
3 - EXHAUST MANIFOLD HEAT SHIELD
9a - 102
ENGINE 5.2L INTERNATIONAL
R1
EXHAUST MANIFOLD (Continued)
(6) Remove vibration damper.
(7) Remove fuel lines (refer to Group 14, Fuel Sys-
tem).
(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. 73).
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 Silicone Rubber Adhe-
sive Sealant, or equivalent, at the joint between tim-
ing 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. 74). Seat
the oil seal in the groove of the tool.
(5) Position the seal and tool onto the crankshaft
(Fig. 75).
(6) Tighten the 4 lower chain case cover bolts to 13
N·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. 76).
(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.
(12) Install water pump and housing assembly
using new gaskets (Refer to 7 - COOLING/ENGINE/
WATER PUMP - INSTALLATION). Tighten bolts to
41 N·m (30 ft. lbs.) torque.
(13) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(14) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(15) Install the cooling system fan. Tighten the
bolts to 23 N·m (17 ft. lbs.) torque.
Fig. 73 Removal of Front Crankshaft Oil Seal
Fig. 74 Placing Oil Seal on Installation Tool 6635
1 - CRANKSHAFT FRONT OIL SEAL
2 - INSTALL THIS END INTO SPECIAL TOOL 6635
Fig. 75 Position Tool and Seal onto Crankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL
3 - TIMING CHAIN COVER
R1
ENGINE 5.2L INTERNATIONAL
9a - 103
TIMING BELT / CHAIN COVER(S) (Continued)
(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/
ENGINE - STANDARD PROCEDURE).
(18) Connect the negative cable to the battery.
TIMING CHAIN
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove Timing Chain Cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL) for correct procedure.
(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. 77).
(4) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
INSPECTION - MEASURING TIMING CHAIN
STRETCH
NOTE: To access timing chain (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S) -
REMOVAL).
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N·m (30 ft. lbs.) torque with cylinder head installed
or 20 N·m (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N·m (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N·m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 78).
Fig. 76 Installing Oil Seal
1 - SPECIAL TOOL 6635
2 - TIMING CHAIN COVER
Fig. 77 Alignment of Timing Marks
1 - TIMING MARKS
Fig. 78 Measuring Timing Chain Wear and Stretch
1 - TORQUE WRENCH
2 - 3.175 MM
(0.125 IN.)
9a - 104
ENGINE 5.2L INTERNATIONAL
R1
TIMING BELT / CHAIN COVER(S) (Continued)
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
(5) If chain is not satisfactory, remove camshaft
sprocket attaching bolt and remove timing chain with
crankshaft and camshaft sprockets.
(6) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(7) Place timing chain around both sprockets.
(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(10) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 79).
(11) Install the camshaft bolt. Tighten the bolt to
47 N·m (35 ft. lbs.) torque.
(12) 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.
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. 77).
(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.
Fig. 79 Alignment of Timing Marks
1 - TIMING MARKS
R1
ENGINE 5.2L INTERNATIONAL
9a - 105
TIMING CHAIN (Continued)
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