Dodge Dakota (R1). Manual — part 483
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(4) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(5) Remove power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(6) Remove
vibration
damper
(Refer
to
9
-
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(7) Loosen oil pan bolts and remove the front bolt
at each side.
(8) Remove the cover bolts.
(9) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
(10) From the inside of the cover tap the front
crankshaft oil seal outward. Be careful not to damage
the timing cover sealing surface.
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar
t GEN II Silicone Rub-
ber Adhesive Sealant, or equivalent, at the joint
between timing chain cover gasket and the oil pan
gasket. Finger tighten the timing chain cover bolts at
this time.
CAUTION: If chain cover is replaced for any reason,
be sure the oil hole (passenger side of cover) is
plugged.
NOTE: Special Tool 6635 must be used to align
cover and seal with crankshaft.
(3) Position the special tool 6635 onto the crank-
shaft (Fig. 82).
(4) Tighten chain case cover bolts to 41 N·m (30 ft.
lbs.) torque. Tighten oil pan bolts to 24 N·m (215 in.
lbs.) torque.
(5) Remove special tool 6635.
(6) Inspect
the
seal
flange
on
the
vibration
damper.
(7) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(8) Install water pump (Refer to 7 - COOLING/EN-
GINE/WATER PUMP - INSTALLATION).
(9) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(10) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(11) Install the cooling system fan (Refer to 7 -
COOLING/ENGINE/FAN
DRIVE
VISCOUS
CLUTCH - INSTALLATION).
(12) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N·m (95 in. lbs.) torque.
(13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the negative cable to the battery.
TIMING BELT/CHAIN
TENSIONER AND PULLEY
DESCRIPTION
The timing chain tensioner is a stamped steel con-
stant tension mechanical design. It is mounted to the
front of the engine, behind the timing chain drive.
OPERATION
The timing chain tension is maintained by routing
the timing chain through the tensioner assembly. A
nylon covered spring steel arm presses on the timing
chain maintaining the correct chain tension.
Fig. 82 Position Special Tool 6635 onto Crankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL
3 - TIMING CHAIN COVER
9 - 120
ENGINE 3.9L
AN
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(4) Rotate crankshaft to align timing marks (Fig.
84) to #1 TDC.
(5) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
(6) Slip crankshaft sprocket onto crankshaft and
compress tensioner shoe by placing a large screw-
driver between crankshaft sprocket and tensioner
shoe (Fig. 83). Compress shoe until hole in shoe lines
up with hole in bracket. Slide a suitable pin into the
holes (Fig. 83) and remove screwdriver.
(7) If tensioner assembly is to be replaced, remove
the three tensioner to block bolts and remove ten-
sioner assembly.
INSPECTION—MEASURING TIMING CHAIN
STRETCH
NOTE: Timing chain tensioner must be removed for
this operation.
(1) Place a scale next to the timing chain so that
any movement of the chain can be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N·m (30 ft. lbs.) torque with cylinder head installed
or 20 N·m (15 ft. lbs.) torque with cylinder head
removed.
With
torque
applied
to
the
camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N·m (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N·m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 85) .
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
Fig. 83 Compressing Tensioner For Chain
Installation
1 - SCREWDRIVER
2 - INSERT PIN HERE
Fig. 84 Alignment of Timing Marks
1 - TIMING MARKS
AN
ENGINE 3.9L
9 - 121
INSTALLATION
(1) If tensioner assembly is being replaced, install
tensioner and mounting bolts. Torque bolts to 24 N·m
(210 in. lbs.).
(2) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on an exact
imaginary center line through both camshaft and
crankshaft bores.
(3) Place timing chain around both sprockets.
(4) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(5) Slide both sprockets evenly over their respec-
tive shafts and verify alignment of timing marks
(Fig. 86) with a straight-edge if necessary.
(6) Install the camshaft bolt. Tighten the bolt to 68
N·m (50 ft. lbs.) torque.
(7) Remove tensioner pin. Again, verify align-
ment of timing marks.
(8) Install timing cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).
(9) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(10) Connect battery negative cable.
(11) Start engine and check for oil and coolant
leaks.
Fig. 85 Measuring Timing Chain Wear and Stretch
1 - TORQUE WRENCH
2 - 3.175 MM (0.125 IN.)
Fig. 86 Alignment of Timing Marks
1 - TIMING MARKS
9 - 122
ENGINE 3.9L
AN
TIMING BELT/CHAIN AND SPROCKETS (Continued)
ENGINE 4.7L
TABLE OF CONTENTS
page
page
ENGINE 4.7L
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 124
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 130
REPAIR DAMAGED OR WORN THREADS . . . 130
FORM-IN-PLACE GASKETS AND SEALERS. . 130
AIR CLEANER ELEMENT
CYLINDER HEAD
CAMSHAFT(S) - LEFT
CAMSHAFT(S) - RIGHT
CYLINDER HEAD COVER(S)
INTAKE/EXHAUST VALVES & SEATS
REFACING . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
ROCKER ARM / ADJUSTER ASSEMBLY
HYDRAULIC LASH ADJUSTER. . . . . . . . . . . . 160
VALVE SPRINGS
VALVE STEM SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 162
ENGINE BLOCK
CYLINDER BORE HONING. . . . . . . . . . . . . . . 162
CONNECTING ROD BEARINGS
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 164
CONNECTING ROD BEARING FITTING . . . . . 164
CORE PLUGS
CRANKSHAFT
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 169
CRANKSHAFT MAIN BEARING - FITTING . . . 169
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
CRANKSHAFT OIL SEAL - FRONT
CRANKSHAFT OIL SEAL - REAR
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 172
REAR SEAL AREA LEAKS . . . . . . . . . . . . . . . 172
FLEX PLATE
PISTON & CONNECTING ROD
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . 173
PISTON RINGS
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 176
PISTON RING FITTING. . . . . . . . . . . . . . . . . . 176
AN
ENGINE 4.7L
9 - 123
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