Dodge Dakota (R1). Manual — part 537
DESCRIPTION
SPECIFICATION
PISTON PIN
Clearance in Piston
0.00635 – 0.01905 mm
(0.00025 – 0.00075 in.)
Diameter
24.996 – 25.001 mm
(0.9841 – 0.9843 in.)
End Play
NONE
Length
75.946 – 76.454 mm
(2.990 – 3.010 in.)
PISTON RINGS
Ring Gap
Compression Rings
0.254 – 0.508 mm
(0.010 – 0.020 in.)
Oil Control (Steel Rails)
0.254 – 1.270 mm
(0.010 – 0.050 in.)
Ring Side Clearance
Compression Rings
0.038 – 0.076 mm
(0.0015 – 0.0030 in.)
Oil Ring (Steel Rails)
0.06 – 0.21 mm
(0.002 – 0.008 in.)
Ring Width
Compression rings
1.971 – 1.989 mm
(0.0776 – 0.0783 in.)
Oil Ring (Steel Rails) –
Max.
3.848 – 3.975 mm
(0.1515 – 0.1565 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC)
21°
Opens (BBDC)
60°
Duration
264°
Intake Valve
Closes (ATDC)
61°
Opens (BBDC)
10°
Duration
250°
Valve Overlap
31°
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
U/S-O/S
Item
Identification
Identification
Location
U/S
Rod/
R or M R-1-4
ect.
Milled flat on
No.8
.0254
mm
Main
(indicating No.
1
crankshaft
(0.001
in.)
Journal
and 4
connecting
counterweight.
rod journal)
and/or
M-2-3 ect.
(indicating No.
2
and 3 main
bearing
journal)
O/S
Hydraulic
L
Diamond-
shaped
.2032
mm
Tappets
stamp top pad
-
(.008 in.)
front of engine
and flat
ground
on outside
surface of
each
O/S tappet
bore.
O/S
Valve
X
Milled pad
.127 mm
Stems
adjacent to
two
(.005 in.)
tapped holes
(3/8 in.) on
each
end of
cylinder
head.
9a - 66
ENGINE 5.2L INTERNATIONAL
R1
ENGINE 5.2L INTERNATIONAL (Continued)
SPECIAL TOOLS
5.2L ENGINE
Oil Pressure Gauge C-3292
Engine Support Fixture C-3487–A
Valve Spring Compressor MD-998772–A
Adaptor 6633
Adaptor 6716A
Valve Guide Sleeve C-3973
Dial Indicator C-3339
Puller C-3688
Front Oil Seal Installer 6635
Cam Bearing Remover/Installer C3132–A
R1
ENGINE 5.2L INTERNATIONAL
9a - 67
ENGINE 5.2L INTERNATIONAL (Continued)
CYLINDER HEAD
DESCRIPTION
The cast iron cylinder heads (Fig. 3) are mounted
to the cylinder block using ten bolts. The spark plugs
are located in the peak of the wedge between the
valves.
OPERATION
The cylinder head closes the combustion chamber
allowing the pistons to compress the air fuel mixture
to the correct ratio for ignition. The valves located in
the cylinder head open and close either to allow clean
air into the combustion chamber or to allow the
exhaust gases out, depending on the stroke of the
engine.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
Camshaft Holder C-3509
Distributor Bushing Puller C-3052
Distributor Bushing Driver/Burnisher C-3053
Piston Ring Compressor C-385
Crankshaft Main Bearing Remover C-3059
Cylinder Bore Gauge C-119
Fig. 3 Cylinder Head Assembly—V-8 Gas Engines
1 - EXHAUST VALVE
2 - SPARK PLUGS
3 - EXHAUST VALVES
4 - SPARK PLUGS
5 - EXHAUST VALVE
6 - INTAKE VALVES
7 - INTAKE VALVES
9a - 68
ENGINE 5.2L INTERNATIONAL
R1
ENGINE 5.2L INTERNATIONAL (Continued)
(3) Remove
the
intake
manifold-to-generator
bracket support rod. Remove the generator.
(4) Remove closed crankcase ventilation system.
(5) Disconnect the evaporation control system.
(6) Remove the air cleaner assembly and air inlet
hose.
(7) Perform the Fuel System Pressure Release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE).
(8) Disconnect the fuel supply line (Refer to 14 -
FUEL
SYSTEM/FUEL
DELIVERY/QUICK
CON-
NECT FITTING - STANDARD PROCEDURE).
(9) Disconnect
accelerator
linkage
and
if
so
equipped, the speed control and transmission kick-
down cables.
(10) Remove distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect heat indicator sending unit wire.
(13) Disconnect heater hoses and bypass hose.
(14) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(15) Remove
intake
manifold
(Refer
to
9
-
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL) and throttle body as an assembly. Dis-
card the flange side gaskets and the front and rear
cross-over gaskets.
(16) Remove exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST
MANIFOLD
-
REMOVAL).
(17) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(18) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(19) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness
exceeds 0.00075 mm/mm (0.00075 inch/inch) times
the span length in inches in any direction, either
replace head or lightly machine the head surface.
FOR EXAMPLE: A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept-
able.
The
cylinder
head
surface
finish
should
be
1.78-3.00 microns (70-125 microinches).
INSTALLATION
(1) Position the new cylinder head gaskets onto
the cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(3) Starting at top center, tighten all cylinder head
bolts, in sequence, to 68 N·m (50 ft. lbs.) torque (Fig.
4). Repeat procedure, tighten all cylinder head bolts
to 143 N·m (105 ft. lbs.) torque. Repeat procedure to
confirm that all bolts are at 143 N·m (105 ft. lbs.)
torque.
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(4) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N·m
(21 ft. lbs.) torque.
(5) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
INSTALLATION) and throttle body assembly.
(6) Install
exhaust
manifolds
(Refer
to
9
-
ENGINE/MANIFOLDS/EXHAUST
MANIFOLD
-
INSTALLATION). Tighten the bolts and nuts to 34
N·m (25 ft. lbs.) torque.
(7) Adjust spark plugs to specifications. (Refer to 8
- ELECTRICAL/IGNITION CONTROL - SPECIFI-
CATIONS). Install the plugs and tighten to 41 N·m
(30 ft. lbs.) torque.
(8) Install coil wires.
(9) Connect heat indicator sending unit wire.
(10) Connect the heater hoses and bypass hose.
(11) Install distributor cap and wires.
(12) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
Fig. 4 Cylinder Head Bolt Tightening Sequence
R1
ENGINE 5.2L INTERNATIONAL
9a - 69
CYLINDER HEAD (Continued)
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