Dodge Dakota (R1). Manual — part 535
ENGINE 5.2L INTERNATIONAL
TABLE OF CONTENTS
page
page
ENGINE 5.2L INTERNATIONAL
HYDROSTATIC LOCK. . . . . . . . . . . . . . . . . . . . 59
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . 60
FORM-IN-PLACE GASKETS . . . . . . . . . . . . . . . 60
REPAIR DAMAGED OR WORN THREADS . . . . 61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 62
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 67
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 69
CYLINDER HEAD COVER GASKET
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
CYLINDER HEAD COVER(S)
INTAKE/EXHAUST VALVES & SEATS
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . 70
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 73
ROCKER ARMS AND PUSH RODS
ENGINE BLOCK
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 74
CYLINDER BORE - HONING . . . . . . . . . . . . . . 74
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 75
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 76
CAMSHAFT & BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CONNECTING ROD BEARINGS
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 78
CONNECTING ROD BEARING - FITTING . . . . . 78
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 79
CRANKSHAFT MAIN BEARINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 80
CRANKSHAFT MAIN BEARING - FITTING . . . . 80
CRANKSHAFT OIL SEAL - FRONT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 81
CRANKSHAFT OIL SEAL - REAR
DISTRIBUTOR DRIVE SHAFT BUSHING
HYDRAULIC TAPPETS
PISTON & CONNECTING ROD
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . . 85
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 87
PISTON RINGS
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 87
PISTON RINGS - FITTING . . . . . . . . . . . . . . . . 87
VIBRATION DAMPER
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9a - 58
ENGINE 5.2L INTERNATIONAL
R1
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 89
REAR MOUNT
LUBRICATION
OIL
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 93
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
OIL PAN
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 96
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 98
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 99
EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 101
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 102
VALVE TIMING
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 102
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . 102
TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 103
TIMING CHAIN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 105
ENGINE 5.2L INTERNATIONAL
DESCRIPTION - ENGINE
The 5.2 Liter (318 CID) eight-cylinder engine is a
V-Type
lightweight,
single
cam,
overhead
valve
engine with hydraulic roller tappets.
The engine lubrication system consists of a rotor
type oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1). This
engine is designed for unleaded fuel.
The engine serial number is stamped into a
machined pad located on the left, front corner of the
cylinder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 2).
STANDARD PROCEDURE - HYDROSTATIC
LOCK
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).
Fig. 1 Firing Order
Fig. 2 Engine Identification Number
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ENGINE 5.2L INTERNATIONAL
9a - 59
(2) Disconnect the battery negative cable.
(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 plugs from the
engine.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (i.e. coolant,
fuel, oil, etc.).
(7) Make 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 engine oil into the cylinders to lubricate
the walls. This will prevent damage on restart.
(10) Install new spark plugs.
(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.
(15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.
STANDARD PROCEDURE - ENGINE
PERFORMANCE
It is important that the vehicle is operating to its
optimum performance level to maintain fuel economy
and the lowest emission levels. If vehicle is not oper-
ating to these standards, refer to Engine Diagnosis.
The following procedures can assist in achieving the
proper engine diagnosis.
(1) Test cranking amperage draw. (Refer to 8 -
ELECTRICAL/BATTERY
SYSTEM/BATTERY
-
STANDARD PROCEDURE), Cold Cranking Test.
(2) Check intake manifold bolt torque.
(3) Perform cylinder compression test. (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING), Cylinder
Compression Pressure Test.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified, (Refer to 8 - ELECTRICAL/
IGNITION CONTROL - SPECIFICATIONS). Tighten
to specifications.
(5) Test resistance of spark plug cables. (Refer to 8
-
ELECTRICAL/IGNITION
CONTROL/SPARK
PLUG CABLE - DIAGNOSIS AND TESTING), Spark
Plug Cables.
(6) Inspect the primary wires. Test coil output volt-
age and primary resistance. Replace parts as neces-
sary.
(Refer
to
8
-
ELECTRICAL/IGNITION
CONTROL - SPECIFICATIONS).
(7) Test fuel pump for pressure. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS).
(8) The air filter elements should be replaced as
specified in Lubrication and Maintenance, (Refer to
LUBRICATION
&
MAINTENANCE/MAINTE-
NANCE SCHEDULES - DESCRIPTION).
(9) Inspect crankcase ventilation system as out
lined in Lubrication and Maintenance (Refer to
LUBRICATION
&
MAINTENANCE/MAINTE-
NANCE SCHEDULES - DESCRIPTION). For emis-
sion controls, (Refer to 25 - EMISSIONS CONTROL -
DESCRIPTION) for service procedures.
(10) Road test vehicle as a final test.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS
There are several places where form-in-place gas-
kets are used on the engine. DO NOT use form-in-
place gasket material unless specified. Care
must be taken when applying form-in-place gaskets.
Bead size, continuity and location are of great impor-
tance. Too thin a bead can result in leakage while too
much can result in spill-over. A continuous bead of
the proper width is essential to obtain a leak-free
joint.
Two types of form-in-place gasket materials are
used in the engine area (Mopar Silicone Rubber
Adhesive Sealant and Mopar Gasket Maker). Each
have different properties and cannot be used inter-
changeably.
MOPAR SILICONE RUBBER ADHESIVE SEALANT
Mopar Silicone Rubber Adhesive Sealant, normally
black in color, is available in 3 ounce tubes. Moisture
in the air causes the sealant material to cure. This
material is normally used on flexible metal flanges.
It has a shelf life of a year and will not properly cure
if over aged. Always inspect the package for the expi-
ration date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normally red in color, is
available in 6 cc tubes. This anaerobic type gasket
material cures in the absence of air when squeezed
between smooth machined metallic surfaces. It will
not cure if left in the uncovered tube. DO NOT use
on flexible metal flanges.
SURFACE PREPARATION
Parts assembled with form-in-place gaskets may be
disassembled
without
unusual
effort.
In
some
9a - 60
ENGINE 5.2L INTERNATIONAL
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ENGINE 5.2L INTERNATIONAL (Continued)
instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
Scrape or wire brush all gasket surfaces to remove
all loose material. Inspect stamped parts to ensure
gasket rails are flat. Flatten rails with a hammer on
a flat plate, if required. Gasket surfaces must be free
of oil and dirt. Make sure the old gasket material is
removed from blind attaching holes.
GASKET APPLICATION
Assembling parts using a form-in-place gasket
requires care.
Mopar Silicone Rubber Adhesive Sealant should be
applied in a continuous bead approximately 3 mm
(0.12 inch) in diameter. All mounting holes must be
circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4
inch) drop is placed in the center of the gasket con-
tact 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 use of a locating dowel is recom-
mended during assembly to prevent smearing the
material off location.
Mopar Gasket Maker should be applied sparingly
to one gasket surface. The sealant diameter should
be 1.00 mm (0.04 inch) or less. Be certain the mate-
rial surrounds each mounting hole. Excess material
can easily be wiped off. Components should be
torqued in place within 15 minutes. The use of a
locating dowel is recommended during assembly to
prevent smearing the material off location.
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.
REMOVAL - ENGINE ASSEMBLY
(1) Scribe hood hinge outlines on hood. Remove the
hood.
(2) Disconnect the battery negative cable.
(3) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(4) Remove the air cleaner.
(5) Disconnect the radiator and heater hoses.
Remove radiator (Refer to 7 - COOLING/ENGINE/
RADIATOR - REMOVAL).
(6) Set fan shroud aside.
(7) Disconnect the vacuum supply lines from the
intake manifold.
(8) Remove the distributor cap and wires.
(9) Disconnect the accelerator linkage.
(10) Remove throttle body.
(11) Perform the Fuel System Pressure release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).
(12) Disconnect the fuel supply line.
(13) Disconnect the starter wires.
(14) Disconnect the oil pressure sending unit wire.
(15) Discharge the air conditioning system, if
equipped(Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/REFRIGERANT
-
STAN-
DARD PROCEDURE).
(16) Disconnect the air conditioning hoses.
(17) Disconnect
the
power
steering
hoses,
if
equipped.
(18) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(19) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(20) Raise and support the vehicle on a hoist.
(21) Disconnect exhaust pipe at manifold.
(22) Refer to Group 21, Transmissions for trans-
mission removal.
CAUTION: DO NOT lift the engine by the intake
manifold.
(23) Install an engine lifting fixture.
(24) The engine and front driving axle (engine/ax-
le/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-
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 a bracket to bell housing
bolt. Separate engine from insulator by removing
upper nut washer assembly and bolt from engine
support bracket.
(25) Lower the vehicle.
(26) Install engine assembly on engine repair
stand.
INSTALLATION - ENGINE ASSEMBLY
(1) Remove engine from the repair stand and posi-
tion in the engine compartment.
(2) Install an engine support fixture.
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ENGINE 5.2L INTERNATIONAL
9a - 61
ENGINE 5.2L INTERNATIONAL (Continued)
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