Dodge Dakota (R1). Manual — part 467
(12) Install the flywheel and torque converter
housing access cover.
(13) Install the engine starter motor.
(14) Connect the exhaust pipe to the hanger and to
the engine exhaust manifold.
(15) Install the oil pan drain plug (Fig. 74).
Tighten the plug to 34 N·m (25 ft. lbs.) torque.
(16) Lower the vehicle.
(17) Connect negative cable to battery.
(18) Fill the oil pan with engine oil to the specified
level.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(19) Start the engine and inspect for leaks.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 2–wire, electrical/mechanical engine oil pres-
sure sensor (sending unit) is located in an engine oil
pressure gallery.
OPERATION
The oil pressure sensor uses two circuits. They are:
• A signal to the PCM relating to engine oil pres-
sure
• A sensor ground through the PCM’s sensor
return
The oil pressure sensor returns a voltage signal
back to the PCM relating to engine oil pressure. This
signal is then transferred (bussed) to the instrument
panel on a CCD bus circuit to operate the oil pres-
sure gauge and the check gauges lamp. Ground for
the sensor is provided by the PCM through a low-
noise sensor return.
OIL PUMP
REMOVAL
The positive-displacement gear-type oil pump is
driven by the distributor shaft, which is driven by a
gear on the camshaft. Oil is siphoned into the pump
through an inlet tube and strainer assembly that is
pressed into the pump body.
The pump incorporates a nonadjustable pressure
relief valve to limit maximum pressure to 517 kPa
(75 psi). In the relief position, the valve permits oil to
bypass through a passage in the pump body to the
inlet side of the pump.
Oil pump removal or replacement will not affect
the distributor timing because the distributor drive
gear remains in mesh with the camshaft gear.
(1) Drain the engine oil.
(2) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(3) Remove the pump-to-cylinder block attaching
bolts. Remove the pump assembly with gasket (Fig.
75).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
INSTALLATION
The positive-displacement gear-type oil pump is
driven by the distributor shaft, which is driven by a
gear on the camshaft. Oil is siphoned into the pump
through an inlet tube and strainer assembly that is
pressed into the pump body.
Fig. 75 Oil Pump Assembly
1 - OIL FILTER ADAPTOR
2 - BLOCK
3 - GASKET
4 - OIL INLET TUBE
5 - OIL PUMP
6 - STRAINER ASSEMBLY
7 - ATTACHING BOLTS
9 - 56
ENGINE 2.5L
AN
OIL PAN (Continued)
The pump incorporates a nonadjustable pressure
relief valve to limit maximum pressure to 517 kPa
(75 psi). In the relief position, the valve permits oil to
bypass through a passage in the pump body to the
inlet side of the pump.
Oil pump removal or replacement will not affect
the distributor timing because the distributor drive
gear remains in mesh with the camshaft gear.
(1) Install the oil pump on the cylinder block using
a replacement gasket. Tighten the bolts to 23 N·m
(17 ft. lbs.) torque.
(2) Install the oil pan and gasket (Refer to 9 -
ENGINE/LUBRICATION/OIL
PAN
-
INSTALLA-
TION).
(3) Fill the oil pan with oil to the specified level.
INTAKE MANIFOLD
DESCRIPTION
The aluminum intake manifold is a single plane
design.
The intake manifold and the exhaust manifold
share a common one piece sealing gasket.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the air inlet hose and resonator from
the throttle body and air cleaner (Fig. 76).
(4) Loosen the accessory drive belt tension and
remove the belt from the power steering pump (Refer
to
7
-
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS - REMOVAL).
(5) Remove the power steering pump and brackets
from the water pump and intake manifold. Secure
power steering pump and bracket out of the way.
(6) Perform fuel system pressure release procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(7) Disconnect fuel supply tube from the fuel rail
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(8) Disconnect the accelerator cable, the cruise
control cable (if equipped), and the transmission line
pressure cable (if equipped) from the throttle body
and remove them from the cable bracket.
CAUTION: When disconnecting the cruise control
connector at the throttle body, DO NOT pry the con-
nector off with pliers or screwdriver. Use finger
pressure only. Prying the connector off could break
it.
(9) Disconnect the electrical connectors. Pull the
harnesses away from the manifold and secure them
so they do not interfere with the manifold removal
and installation process.
• The throttle position sensor.
• The idle air control motor.
• The coolant temperature sensor at the thermo-
stat.
Fig. 76 Air Cleaner, Resonator and Air Inlet Hose
Removal and Installation
1 - AIR CLEANER ASSEMBLY
2 - NUT AND WASHER
3 - RESONATOR ASSEMBLY
4 - AIR INLET HOSE
AN
ENGINE 2.5L
9 - 57
OIL PUMP (Continued)
• The manifold air temperature sensor at the
intake manifold.
• The fuel injectors.
• The oxygen sensor.
(10) Disconnect the crankcase ventilation (CCV)
vacuum hose and manifold absolute pressure (MAP)
sensor vacuum hose connector at the intake mani-
fold.
(11) Disconnect vacuum hose from vacuum port on
the intake manifold.
(12) Disconnect CCV hose at the cylinder head
cover (Fig. 77).
(13) Remove the molded vacuum harness.
(14) Disconnect the vacuum brake booster hose at
the intake manifold.
(15) Remove bolts 2 through 5 securing the intake
manifold to the cylinder head (Fig. 78). Slightly
loosen bolt No.1 and nuts 6 and 7.
(16) Remove the intake manifold and gaskets.
Drain the coolant from the manifold.
CLEANING
CAUTION: DO NOT allow foreign material to enter
either the intake manifold ports, or the cylinder
head ports.
Clean the intake manifold to cylinder head mating
surfaces.
INSPECTION
Inspect manifold to cylinder head mating surfaces
for cracks and/or pitting. Inspect manifold for warp
or twist.
INSTALLATION
(1) Clean the intake manifold and cylinder head
mating surfaces. DO NOT allow foreign material
to enter either the intake manifold or the ports
in the cylinder head.
(2) Install the new intake manifold gasket over the
locating dowels.
(3) Position the manifold in place and finger
tighten the mounting bolts.
(4) Tighten the fasteners in sequence and to the
specified torque (Fig. 78).
• Fastener No.1—Tighten to 41 N·m (30 ft. lbs.)
torque.
• Fasteners Nos.2 through 5—Tighten to 31 N·m
(23 ft. lbs.) torque.
• Fasteners Nos.6 and 7—Tighten to 23 N·m (17
ft. lbs.) torque.
(5) Connect fuel supply tube to the fuel rail inlet
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(6) Pull out on the fuel supply tube to ensure that
it is locked in place.
(7) Connect the molded vacuum hoses to the vac-
uum port on the intake manifold and the cylinder
head cover.
(8) Connect the electrical connectors.
• The throttle position sensor.
• The idle air control motor.
• The coolant temperature sensor at the thermo-
stat housing.
• The fuel injectors.
• The air manifold temperature sensor.
• The oxygen sensor.
(9) Connect the CCV vacuum hose and MAP sen-
sor vacuum hose connectors to the throttle body.
(10) Install the power steering pump and bracket
assembly to the water pump and intake manifold.
Hand start the three (3) tensioner bracket to p/s
pump to intake manifold bolts and the two (2) ten-
sioner bracket to water pump bolts.
(11) Tighten the power steering pump bolts to 28
N·m (21 ft. lbs.) Tighten the tensioner bracket to
water pump bolts to 28 N·m (21 ft. lbs.).
(12) Connect the accelerator cable, cruise control
cable (if equipped), and the transmission line pres-
sure cable (if equipped) to the hold-down bracket and
the throttle lever.
(13) Install and tension the accessory drive belt.
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION).
Fig. 77 Crankcase Ventilation (CCV) Hose—2.5L
1 - AIR INLET FITTING
2 - AIR FILTER COVER
3 - FIXED ORIFICE FITTING
9 - 58
ENGINE 2.5L
AN
INTAKE MANIFOLD (Continued)
CAUTION: Ensure that the accessory drive belt is
routed correctly. Failure to do so can cause the
water pump to turn in the opposite direction result-
ing in engine overheating. Refer to Group 7, Cool-
ing System for the proper procedure.
(14) Connect the air inlet hose and resonator to
the throttle body and the air cleaner. Tighten clamps
to 4 N·m (35 in. lbs.).
(15) Connect the battery negative cable.
(16) Start the engine and check for leaks.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifold is constructed of cast iron
and has a ball flange designed exhaust pipe mount-
ing flange.
The exhaust manifold and the intake manifold
share a common one piece sealing gasket.
OPERATION
The exhaust manifold collects the engine exhaust
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipe attached to the
manifold.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Raise the vehicle.
(4) Disconnect the exhaust pipe from the engine
exhaust manifold.
(5) Lower the vehicle.
(6) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(7) Remove fasteners 2 through 5 and remove the
intake manifold (Fig. 78).
(8) Remove fasteners 1, 6 and 7 and remove the
engine exhaust manifold (Fig. 78).
CLEANING
Clean mating surfaces on cylinder head and mani-
fold, wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks, Inspect mating sur-
faces of manifold for flatness with a straight edge.
Seal surfaces must be flat within 0.1 mm (0.004 inch)
overall.
INSTALLATION
(1) Clean the intake and engine exhaust manifolds
and cylinder head mating surfaces. DO NOT allow
foreign material to enter either the intake man-
ifold or the ports in the cylinder head.
(2) Install a new intake manifold gasket over the
alignment dowels on the cylinder head.
(3) Install the engine exhaust manifold assembly.
Exhaust manifold must be centrally located
over the end studs and spacer (Fig. 78).
(4) Tighten bolt No.1 to 41 N·m (30 ft. lbs.) torque
(Fig. 78).
(5) Install the intake manifold on the cylinder
head dowels (Fig. 78).
(6) Install bolts 2 through 5 (Fig. 78). Tighten
these bolts to 31 N·m (23 ft. lbs.) torque.
(7) Install new engine exhaust manifold spacers
over the engine exhaust manifold mounting studs in
the cylinder head (Fig. 78).
(8) Tighten nuts 6 and 7 to 23 N·m (17 ft. lbs.)
torque (Fig. 78).
(9) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
INSTALLATION).
(10) Raise the vehicle.
(11) Connect the exhaust pipe to the engine
exhaust manifold. Tighten the bolts to 31 N·m (23 ft.
lbs.) torque.
(12) Lower the vehicle.
(13) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the battery negative cable.
(15) Start the engine and check for leaks.
Fig. 78 Intake/Exhaust Manifold Removal/Installation
AN
ENGINE 2.5L
9 - 59
INTAKE MANIFOLD (Continued)
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