Dodge Dakota (R1). Manual — part 473
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
OS-US
Item
Identification
Location of
Identification
U/S
Crankshaft
R or M M-2-3
ect.
Milled flat on
.0254
MM
(indicating No.
2 &
No. eight
(.001
IN.)
3 main
bearing
crankshaft
journal) and/or counterweight.
R-1-4 ect.
(indicating No.
1 &
4 connecting
rod
journal)
O/S
Tappets
L
3/8
9
.2032
mm
diamound
(.008 in.)
-shaped
stamp Top
pad
— Front of
engine and
flat
ground on
outside
surface
of each O/S
tappet bore.
O/S
Valve
Stems
X
Milled pad
.127 mm
adjacent to
two
(0.005
in.)
3/8
9
tapped
holes on
each
end of
cylinder
head.
SPECIAL TOOLS
ENGINE—3.9L
Oil Pressure Gauge C-3292
Engine Support Fixture C-3487–A
Valve Spring Compressor MD-998772–A
Adapter 6633
Adapter 6716A
9 - 80
ENGINE 3.9L
AN
ENGINE 3.9L (Continued)
Valve Guide Sleeve C-3973
Dial Indicator C-3339
Puller C-3688
Front Oil Seal Installer 6635
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
AN
ENGINE 3.9L
9 - 81
ENGINE 3.9L (Continued)
AIR CLEANER ELEMENT
REMOVAL
Housing removal is not necessary for element (fil-
ter) replacement.
(1) Pry up spring clips from housing cover (spring
clips retain cover to housing).
(2) Release housing cover from locating tabs on
housing (Fig. 6) and remove cover.
(3) Remove air cleaner element (filter) from hous-
ing.
(4) Clean inside of housing before replacing ele-
ment.
INSTALLATION
(1) Install element into housing.
(2) Position housing cover into housing locating
tabs.
(3) Pry up spring clips and lock cover to housing.
CYLINDER HEAD
DESCRIPTION
The cast iron cylinder heads (Fig. 7) are mounted
to the cylinder block using eight 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 to either allow clean
air into the combustion chamber or to allow the
exhaust gases out, depending on the stroke of the
engine.
DIAGNOSIS AND TESTING—CYLINDER HEAD
GASKET FAILURE
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
• Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
• Loss of engine power
Pressure Tester Kit 7700
Bloc–Chek–Kit C-3685–A
Fig. 6 Air Cleaner Housing Assembly
1 - AIR CLEANER ELEMENT COVER
2 - TABS
3 - HOUSING
Fig. 7 Cylinder Head Assembly—3.9L Engine
1 - SPARK PLUGS
2 - SPARK PLUG
3 - INTAKE VALVE
4 - EXHAUST VALVES
5 - INTAKE VALVES
6 - EXHAUST VALVE
9 - 82
ENGINE 3.9L
AN
ENGINE 3.9L (Continued)
• Engine misfiring
• Poor fuel economy
• Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
• Engine overheating
• Loss of coolant
• Excessive steam (white smoke) emitting from
exhaust
• Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test in this
section. An engine cylinder head gasket leaking
between adjacent cylinders will result in approxi-
mately a 50–70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE
PRESSURE
BUILT
UP,
BY
CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 158 kPa (23 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester’s pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
The alloy cast iron cylinder heads (Fig. 8) are held
in place by eight bolts. The spark plugs are located
at the peak of the wedge between the valves.
(1) Disconnect the battery negative cable from the
battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(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, air in-let hose and res-
onator.
(7) Perform fuel system pressure release procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(8) Disconnect the fuel supply line from the fuel
rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(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 coolant temperature sending unit
wire.
(13) Disconnect heater hoses and bypass hose.
(14) Disconnect the vacuum supply hoses from the
intake manifold.
(15) Disconnect the fuel injector harness and
secure out of the way.
(16) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(17) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(18) Remove exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST
MANIFOLD
-
REMOVAL).
(19) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(20) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(21) 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.
AN
ENGINE 3.9L
9 - 83
CYLINDER HEAD (Continued)
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