Dodge Dakota (R1). Manual — part 526
(56) Install the lower front splash shield.
(57) Fill the transmission. Refer to Group 21,
Transmission for the procedure.
(58) Lower the vehicle on the hoist.
(59) Install both of the wiper arms on the vehicle.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARMS - INSTALLATION).
(60) With assistance from another person, install
the hood assembly (Fig. 25). Torque the bolts to 47
N·m (35 ft. lbs.).
(61) Connect the engine compartment lamp electri-
cal connector.
(62) Recharge the refrigerant. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/REFRIG-
ERANT - STANDARD PROCEDURE) .
(63) Connect the positive and negative battery
cables.
(64) Fill the cooling system (Refer to 7 - COOL-
ING/ENGINE - STANDARD PROCEDURE).
(65) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
(66) Fill engine oil. Start engine and check for
leaks.
Fig. 23 Cowl Grille Position & Orientation
1 - PUSHPINS
2 - COWL GRILLE RETAINING NUTS
3 - PUSHPINS
4 - COWL GRILLE
Fig. 24 Refrigerant Lines At Compressor
1 - COMPRESSOR ELECTRICAL CONNECTOR
2 - REFRIGERANT LINE RETAINING BOLTS
3 - COMPRESSOR RETAINING BOLTS
4 - H-BLOCK
Fig. 25 Hood Position & Orientation
1 - HOOD RETAINING BOLTS
2 - ENGINE COMPARTMENT LAMP
3 - ENGINE COMPARTMENT LAMP ELECTRICAL CONNECTOR
9a - 22
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL (Continued)
SPECIFICATIONS
ENGINE SPECIFICATIONS
DESCRIPTION
SPECIFICATIONS
Type
425 CX2
Number of cylinders
4
Bore
92 mm
Stroke
94 mm
Capacity
2499.5cc
Injection order
1–3–4–2
Compression ratio
21 : 1 (+/
2
0.5)
Gasket
Asbestos free
Crankshaft
Front journal diameter
Nominal
62.985-63.005 mm
2
0.25
62.735-62.755 mm
2
0.125
62.860-62.880 mm
Front bearing diameter
Nominal
63.043-63.088 mm
2
0.25
62.793-62.838
2
0.125
62.919-62.964 mm
Clearance between
journal and bearing:
0.038-0.103 mm
Center journal diameter
Nominal
63.005-63.020 mm
2
0.25
62.755-62.770 mm
2
0.125
62.880-62.895 mm
Center bearing diameter
Nominal
63.050-63.093 mm
2
0.25
62.800-62.843 mm
2
0.125
62.925-62.968 mm
Clearance between
journal and bearing:
0.030-0.088 mm
Rear journal diameter
Nominal
79.980-80.000 mm
2
0.25
79.730-79.750 mm
2
0.125
79.855-79.875 mm
Rear bearing diameter
Nominal
80.045-80.070 mm
2
0.25
79.795-79.820 mm
2
0.125
79.920-79.945 mm
DESCRIPTION
SPECIFICATIONS
Clearance between
journal and bearing:
0.045-0.090 mm
Wear limit: 0.200 mm.
Connecting rod journal
Nominal
53.940-53.955 mm
2
0.25
53.690-53.705 mm
2
0.125
53.815-53.830 mm
Connecting rod bearing
Nominal
53.977-54.016 mm
2
0.25
53.727-53.766 mm
2
0.125
53.852-53.891 mm
Clearance between
journal and bearing:
0.022-0.076 mm
Wear limit: 0.200 mm
Crankshaft end play
End play
0.080-0.280 mm
Adjustment
Thrust washers
Thrust washers available:
2.31-2.36 mm
2.41-2.46 mm
2.51-2.56 mm
Main bearing carriers
Internal diameter
Front
67.025-67.050 mm
Center
66.670-66.687 mm
Rear
85.985-86.005 mm
Liners
Internal diameter
91.997-92.015 mm
Protrusion
0.01-0.06 mm
Adjustment
Shims
Available shims:
0.15 mm
0.17 mm
0.20 mm
0.23 mm
0.25 mm
Cylinder head
Minimum thickness
89.95-90.05 mm
Gaskets thickness
1.41 mm +/
2
0.08, 0
notches
1.61 mm +/
2
0.08, 1
notch
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ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 23
ENGINE 2.5L VM DIESEL INTERNATIONAL (Continued)
DESCRIPTION
SPECIFICATIONS
1.51 mm +/
2
0.08, 2
notches
End plates:
Height
89.92
2
90.00 mm
Connecting rods
Weight (without the crank
bearing): 966 grams
Small end bearing
Internal diameter
Minimum
30.035 mm
Maximum
30.050 mm
Crankshaft bearings
Standard Internal
diameter
53.977
2
54.016 mm
Pistons
Skirt diameter
91.918-91.932 mm
(measured at
approximately 10 mm
above the bottom of the
skirt).
Piston clearance:
0.065-0.083 mm
Top of piston to cylinder
head
0.80-0.89 mm
Piston protrusion
0.53 - 0.62 Fit gasket
Number (1.41), 0 notches
or holes
0.73 - 0.82 Fit gasket
Number (1.61), 1 notch
or hole
0.63 - 0.72 Fit gasket
Number (1.51), 2 notches
or holes
Piston pins
Type
Fully floating
Pin diameter
29.992-29.996 mm
Clearance
0.004-0.012 mm
Piston rings
Clearance in groove:
Top
0.080-0.130 mm
Second
0.070-0.110 mm
Oil control
0.040-0.080 mm
Fitted gap:
Top
0.30 - 0.45 mm
Second
0.30 - 0.45 mm
DESCRIPTION
SPECIFICATIONS
Oil control
0.25 - 0.50 mm
Camshaft
Journal diameter, front
53.495-53.51 mm
Bearing clearance
0.030-0.095 mm
Center
53.45-53.47 mm
Bearing clearance
0.07-0.14 mm
Rear
53.48-53.50 mm
Bearing clearance
0.04-0.11 mm
Tappets
Outside diameter
22.195-22.212 mm
Rocker gear
Shaft diameter
21.979-22.00 mm
Bush internal diameter
22.020-22.041 mm
Assembly clearance
0.020-0.062 mm
Valves
Intake valve:
Opens
26° B.T.D.C.
Closes
58° A.B.D.C.
Exhaust valve:
Opens
66° B.B.D.C.
Closes
36° A.T.D.C.
Face angle:
Intake
55° 30’ - 55° 40’
Exhaust
45° 25’ - 45° 35’
Head diameter:
Intake
40.05-40.25 mm
Exhaust
33.8-34.0 mm
Head stand down:
Intake
1.08-1.34 mm
Exhaust
0.99-1.25 mm
Stem diameter:
Intake
7.940-7.960 mm
Exhaust
7.922-7.940 mm
Clearance in guide:
Intake
0.040-0.075 mm
Exhaust
0.060-0.093 mm
Valve guide
Inside diameter
8.0-8.015 mm
Fitted height
13.5-14 mm
9a - 24
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL (Continued)
DESCRIPTION
SPECIFICATIONS
Valve springs
Free length
44.65 mm
Fitted length
38.6 mm
Load at fitted length
34 +/
2
6% Kg
Load at top of lift
92.5 +/- 4% Kg
Number of coils
5.33 Valve timing
Lubrication
System pressure at 4000
rev/min
3.5 to 5.0 bar (oil at
90-100°C)
Pressure relief valve
opens
6.84 bar
Pressure relief valve
spring - free length
57.5 mm
Oil pump:
Outer rotor end float
0.030-0.107 mm
Inner rotor end float
0.030-0.107 mm
Outer rotor to body diam.
clearance
0.130-0.230 mm
Rotor body to drive gear
clearance (pump not
fitted)
0.30-0.50 mm
TORQUE SPECIFICATIONS
DESCRIPTION
TORQUE
Adaptor Plate to Block
Nuts (6)
27 N·m ( 20 ft. lbs.)
Automatic Belt Tensioner to Block
Bolts (2)
121 N·m
Automatic Belt Tensioner to Mounting Bracket
Bolt (1)
75 N·m
Generator bracket
Mounting bolts (6 mm)
10 N·m
Mounting bolts (8 mm)
24.4 N·m
Generator
Mounting bolt
47 N·m
Camshaft thrust plate
Bolts
24 N·m
Connecting rod
Mounting bolt
29.5 N·m +60°
Crankshaft bearing
Carrier screw
42 N·m
DESCRIPTION
TORQUE
Crankshaft pulley
Locknut
160 N·m
Crossmember
Bolts
42 N·m
Diesel delivery
Union nut
18.5 N·m
EGR valve
To intake manifold
26 N·m
EGR tube
To EGR valve
27 N·m
Engine mount—Front
Engine support bracket
61 N·m
Support Cushion
47 N·m
Support cushion bracket
bolts
54 N·m
Support cushion bracket
stud nuts
41 N·m
Support Cushion through
bolt
65 N·m
Engine mount—Rear
Transmission support
bracket
46 N·m
Support Cushion nuts
75 N·m
Support Cushion through
bolt
65 N·m
Exhaust down pipe
To turbocharger
22 N·m
Exhaust heat shield
Screws
11 N·m
Exhaust manifold collar
Mounting nut
24.5 to 29.5 N·m
Exhaust manifold
Mounting nut
32.5 N·m
Fan drive
To fan hub
56 N·m
Flywheel
Lock bolt
20 N·m +60°
Front timing cover
6 mm bolts
10 N·m
8 mm bolts
26 N·m
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 25
ENGINE 2.5L VM DIESEL INTERNATIONAL (Continued)
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