Dodge Dakota (R1). Manual — part 471
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 50° to 60°
for proper seating of rings (Fig. 3).
(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50° to 60°
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed.
Never use the following to clean gasket surfaces:
• Metal scraper
• Abrasive pad or paper to clean cylinder block
and head
• High speed power tool with an abrasive pad or a
wire brush (Fig. 4)
Only use the following for cleaning gasket surfaces:
• Solvent or a commercially available gasket
remover
• Plastic or wood scraper (Fig. 4)
• Drill motor with 3M Roloc™ Bristle Disc (white
or yellow) (Fig. 4)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 5).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopar
t
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
Fig. 4 PROPER TOOL USAGE FOR SURFACE
PREPARATION
1 - ABRASIVE PAD
2 - 3M ROLOC™ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
9 - 72
ENGINE 3.9L
AN
ENGINE 3.9L (Continued)
STANDARD PROCEDURE—HYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N·m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N·m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill
engine
crankcase
with
the
specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
• Drilling out worn or damaged threads.
• Tapping the hole with a special Heli-Coil Tap, or
equivalent.
• Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when
applying
form-in-place
gaskets
to
assure
obtaining the desired results. Do not use form-in-
place gasket material unless specified. Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopar
t
Engine RTV GEN II, Mopar
t ATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPAR
t ENGINE RTV GEN II
Mopar
t Engine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains
adhesion
and
sealing
properties
when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
Fig. 5 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
AN
ENGINE 3.9L
9 - 73
ENGINE 3.9L (Continued)
MOPAR
t ATF RTV
Mopar
t ATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic
transmission
fluid,
engine
coolants,
and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPAR
t GASKET MAKER
Mopar
t Gasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPAR
t GASKET SEALANT
Mopar
t Gasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
vent corrosion. Mopar
t Gasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it’s easier then using precut gas-
kets.
Mopar
t Gasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
Mopar
t Engine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
Mopar
t Gasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
REMOVAL
(1) Scribe hood hinge outlines on hood. Remove the
hood.
(2) Remove the battery.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove the air cleaner, air in-let hose and res-
onator assembly.
(5) Disconnect the radiator and heater hoses.
Remove radiator. (Refer to 7 - COOLING/ENGINE/
RADIATOR - REMOVAL).
(6) Disconnect the vacuum lines from the intake
manifold.
(7) Remove the distributor cap and wiring.
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL).
(9) Remove throttle body (Refer to 14 - FUEL SYS-
TEM/FUEL
INJECTION/THROTTLE
BODY
-
REMOVAL).
(10) Perform the Fuel System Pressure Release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).
(11) Disconnect the starter wires.
(12) Disconnect the oil pressure wire.
(13) Discharge the air conditioning system, if
equipped. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/REFRIGERANT
-
STAN-
DARD PROCEDURE).
(14) Disconnect the air conditioning hoses.
(15) Disconnect
the
power
steering
hoses,
if
equipped.
(16) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(17) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(18) Raise and support the vehicle on a hoist.
(19) Disconnect exhaust pipe at manifolds.
(20) RemoveTransmission. Refer to 21 - TRANS-
MISSION AND TRANSFER CASE.
CAUTION: DO NOT lift the engine by the intake
manifold.
(21) Install an engine lifting fixture.
(22)
2WD VEHICLES—Remove engine front
mount bolts.
(23) 4WD
VEHICLES—The
engine
and
front
driving axle (engine/axle/transmission) are connected
through insulators and support brackets. Separate
the engine as follows:
• LEFT SIDE—Remove 2 bolts attaching (engine/
pinion nose/transmission) bracket to transmission
bell housing. Remove 2 bracket to pinion nose adap-
9 - 74
ENGINE 3.9L
AN
ENGINE 3.9L (Continued)
tor bolts. Separate engine from insulator by removing
upper nut washer assembly and bolt from engine
support bracket.
• RIGHT SIDE—Remove 2 bracket to axle (dis-
connect housing) bolts and 1 bracket to bell housing
bolt. Separate engine from insulator by removing
upper nut washer assembly and bolt from engine
support bracket.
(24) Lower the vehicle.
(25) On automatic transmission vehicles, discon-
nect the engine from the torque converter drive plate.
On manual transmission vehicles, move engine for-
ward until drive pinion shaft clears the clutch disc.
Remove engine from engine compartment.
(26) Install engine assembly on engine repair
stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Install transmission.
(5) Install the front engine mounts (Refer to 9 -
ENGINE/ENGINE MOUNTING/FRONT MOUNT -
INSTALLATION).
(6) Install exhaust pipe to manifold.
(7) Lower the vehicle.
(8) Remove engine lifting fixture.
(9) Install the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - INSTALLATION).
(10) Install starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - INSTALLA-
TION).
(11) Connect power steering hoses, if equipped.
(12) Connect air conditioning hoses.
(13) Evacuate and charge the air conditioning sys-
tem, if equipped (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/REFRIGERANT
-
STANDARD PROCEDURE).
(14) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(15) Connect the accelerator linkage (Refer to 14 -
FUEL
SYSTEM/FUEL
INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION).
(16) Connect the starter wires.
(17) Connect the oil pressure sensor wire.
(18) Install the distributor cap and wiring.
(19) Connect the vacuum lines.
(20) Connect the fuel supply line (Refer to 14 -
FUEL
SYSTEM/FUEL
DELIVERY/QUICK
CON-
NECT FITTING - STANDARD PROCEDURE).
(21) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION). Connect
the radiator hoses and heater hoses.
(22) Install fan shroud in position.
(23) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(24) Install the air cleaner, resonator assembly and
air in-let hose. Tighten clamps to 4 N·m (35 in. lbs.).
(25) Install the battery.
(26) Warm engine and adjust.
(27) Install hood and line up with the scribe
marks.
(28) Road test vehicle.
SPECIFICATIONS
TORQUE
TORQUE CHART 3.9L ENGINE
DESCRIPTION
N·m
In.
Ft.
Lbs.
Lbs.
Camshaft Sprocket—Bolt
68
—
50
Camshaft Thrust
Plate—Bolts
24
210
—
Timing Chain Case
Cover—
41
—
30
Bolts
Connecting Rod
Cap—Bolts
61
—
45
Main Bearing Cap—Bolts
115
—
85
Crankshaft Pulley—Bolts
24
210
—
Cylinder Head—Bolts
Step 1
68
—
50
Step 2
143
—
105
Cylinder Head Cover—
Bolts
11
95
—
Engine Support Bracket
41
—
30
to Block (4wd)—Bolts
Exhaust Manifold to
Cylinder
34
—
25
Head—bolts/nuts
Flywheel—Bolts
75
—
55
Front Insulator—through
Bolts
95
—
70
Front Insulator to
Support
Bracket (4wd)
—Stud Nut
41
—
30
—Through Bolt/Nut
102
—
75
Front Insulator to Block—
95
—
70
AN
ENGINE 3.9L
9 - 75
ENGINE 3.9L (Continued)
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