Dodge Dakota (R1). Manual — part 536
(3) Raise and support the vehicle on a hoist.
(4) Install the engine front mounts.
(5) Refer to Group, 21 Transmissions for transmis-
sion installation.
(6) Install the inspection plate.
(7) Remove transmission support.
(8) Install exhaust pipe to manifold.
(9) Lower the vehicle.
(10) Remove engine lifting fixture.
(11) Install the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - INSTALLATION).
(12) Install starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - INSTALLA-
TION).
(13) Connect power steering hoses, if equipped.
(14) Connect air conditioning hoses.
(15) Evacuate and charge the air conditioning sys-
tem, if equipped (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/REFRIGERANT
-
STANDARD PROCEDURE).
(16) Using a new gasket, install throttle body.
Tighten the throttle body bolts to 23 N·m (200 in.
lbs.) torque.
(17) Connect the accelerator linkage.
(18) Connect the starter wires.
(19) Connect the oil pressure sending unit wire.
(20) Install the distributor cap and wiring.
(21) Connect the vacuum supply lines to the
intake manifold.
(22) Connect the fuel supply lines.
(23) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION). Connect
the radiator hoses and heater hoses.
(24) Install fan shroud in position.
(25) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(26) Install the air cleaner.
(27) Install the battery.
(28) Warm engine and adjust.
(29) Install hood and line up with the scribe
marks.
(30) Road test vehicle.
SPECIFICATIONS
TORQUE
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Camshaft Sprocket—Bolt
68
50
—
Camshaft Thrust Plate—Bolts
24
—
210
Chain Case Cover—Bolts
41
30
—
Connecting Rod Cap—Bolts
61
45
—
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
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 to
Block—Bolts (4WD)
41
30
—
Exhaust Manifold to Cylinder
Head—Bolts/Nuts
34
25
—
Flywheel—Bolts
75
55
—
Front Insulator—Through
bolt/nut
95
70
—
Front Insulator to Support
Bracket—
Stud Nut (4WD)
41
30
—
Through Bolt/Nut
102
75
—
Front Insulator to Block—Bolts
(2WD)
95
70
—
Generator—Mounting Bolts
41
30
—
Intake Manifold—Bolts
Refer to
Procedure
Oil Pan—Bolts
24
—
215
Oil Pan—Drain Plug
34
25
—
Oil Pump—Mounting Bolts
41
30
—
Oil Pump Cover—Bolts
11
—
95
Rear Insulator to Bracket—
Through Bolt (2WD)
68
50
—
Rear Insulator to Crossmember
Support Bracket—Nut (2WD)
41
30
—
Rear Insulator to
Crossmember—Nuts (4WD)
68
50
—
Rear Insulator to
Transmission—Bolts (4WD)
Rear Insulator Bracket—Bolts
(4WD Automatic)
68
50
—
Rear Support Plate to Transfer
Case—Bolts
Rocker Arm—Bolts
28
21
—
Spark Plugs
41
30
—
Starter Motor—Mounting Bolts
68
50
—
Thermostat Housing—Bolts
25
—
225
Throttle Body—Bolts
23
—
200
9a - 62
ENGINE 5.2L INTERNATIONAL
R1
ENGINE 5.2L INTERNATIONAL (Continued)
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Torque Converter Drive
Plate—Bolts
31
—
270
Transfer Case to Insulator
Mounting Plate—Nuts
204
150
—
Transmission Support Bracket—
Bolts (2WD)
68
50
—
Vibration Damper—Bolt
183
135
—
Water Pump to Timing Chain
Case Cover—Bolts
41
30
—
5.2L ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION
SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type
90° V-8 OHV
Bore and Stroke
99.3 x 84.0 mm
(3.91 x 3.31 in.)
Displacement
5.2L
(318 c.i.)
Compression Ratio
9.1:1
Firing Order
1–8–4–3–6–5–7–2
Lubrication
Pressure Feed—
Full Flow Filtration
Cooling System
Liquid Cooled—
Forced Circulation
Cylinder Block
Cast Iron
Crankshaft
Nodular Iron
Cylinder Head
Cast Iron
Combustion Chambers
Wedge-High Swirl
Valve shrouding
Camshaft
Nodular Cast Iron
Pistons
Aluminum Alloy w/strut
Connecting Rods
Forged Steel
Cylinder Compression
689.5 kPa
Pressure (Min.)
(100 psi)
DESCRIPTION
SPECIFICATION
CAMSHAFT
Bearing Diameter
No. 1
50.800 – 50.825 mm
(2.000 – 2.001 in.)
No. 2
50.394 – 50.419 mm
(1.984 – 1.985 in.)
No. 3
50.013 – 50.038 mm
(1.969 – 1.970 in.)
No. 4
49.606 – 49.632 mm
(1.953 – 1.954 in.)
No. 5
39.688 – 39.713 mm
(1.5625 – 1.5635 in.)
Bearing Journal Diameter
No. 1
50.749 – 50.775 mm
(1.998 – 1.999 in.)
No. 2
50.343 – 50.368 mm
(1.982 – 1.983 in.)
No. 3
49.962 – 49.987 mm
(1.967 – 1.968 in.)
No. 4
49.555 – 49.581 mm
(1.951 – 1.952 in.)
No. 5
39.637 – 39.662 mm
(1.5605 – 1.5615 in.)
Bearing to Journal
Clearance
Standard
0.0254 – 0.0762 mm
(0.001 – 0.003 in.)
Service Limit
0.127 mm
(0.005 in.)
End Play
0.051 – 0.254 mm
(0.002 – 0.010 in.)
CONNECTING RODS
Piston Pin bore Diameter
24.966 – 24.978 mm
(0.9829 – 0.9834 in.)
Side Clearance
0.152 – 0.356 mm
(0.006 – 0.014 in.)
R1
ENGINE 5.2L INTERNATIONAL
9a - 63
ENGINE 5.2L INTERNATIONAL (Continued)
DESCRIPTION
SPECIFICATION
CRANKSHAFT
Rod Journal
Diameter
53.950 – 53.975 mm
(2.124 – 2.125 in.)
Out of Round (Max.)
0.0254 mm
(0.001 in.)
Taper (Max.)
0.0254 mm
(0.001 in.)
Bearing Clearance
0.013 – 0.056 mm
(0.0005 – 0.0022 in.)
Service Limit
0.0762 mm
(0.003 in.)
Main Bearing Journal
Diameter
63.487 – 63.513 mm
(2.4995 – 2.5005in.)
Out of Round (Max.)
0.127 mm
(0.001 in.)
Taper (Max.)
0.0254 mm
(0.001 in.)
Bearing Clearance
(#1 Journal)
0.013 – 0.038 mm
(0.0005 – 0.0015 in.)
(#2-5 Journals)
0.013 – 0.051 mm
(0.0005 – 0.002 in.)
Service Limit
(#1 Journal)
0.0381 mm
(0.0015 in.)
(#2-5 Journals)
0.064 mm
(0.0025 in.)
End Play
0.051 – 0.178 mm
(0.002 – 0.007 in.)
Service Limit
0.254 mm
(0.010 in.)
CYLINDER BLOCK
Cylinder Bore
Diameter
99.308 – 99.371 mm
(3.9098 – 3.9122 in.)
Out of Round (Max.)
0.025 mm
(0.001 in.)
Taper (Max.)
0.025 mm
DESCRIPTION
SPECIFICATION
(0.001 in.)
Oversize Limit
1.016 mm
(0.040 in.)
Lifter Bore Diameter
22.99 – 23.01 mm
(0.9051 – 0.9059 in.)
Distributor Drive Bushing
(Press Fit)
Bushing to Bore
Interference
0.0127 – 0.3556 mm
(0.0005 – 0.0140 in.)
Shaft to Bushing
Clearance
0.0178 – 0.0686 mm
(0.0007 – 0.0027 in.)
CYLINDER HEAD
Valve Seat
Angle
44.25° – 44.75°
Runout (Max.)
0.0762 mm
(0.003 in.)
Width (Finish)
Intake
1.016 – 1.524 mm
(0.040 – 0.060 in.)
Exhaust
1.524 – 2.032 mm
(0.060 – 0.080 in.)
VALVES
Face Angle
43.25° – 43.75°
Head Diameter
Intake
48.666 mm
(1.916 in.)
Exhaust
41.250 mm
(1.624 in.)
Length (Overall)
Intake
124.28 – 125.92 mm
(4.893 – 4.918 in.)
Exhaust
124.64 – 125.27 mm
(4.907 – 4.932 in.)
Lift (@ zero lash)
10.973 mm
(0.432 in.)
Stem Diameter
7.899 – 7.925 mm
(0.311 – 0.312 in.)
9a - 64
ENGINE 5.2L INTERNATIONAL
R1
ENGINE 5.2L INTERNATIONAL (Continued)
DESCRIPTION
SPECIFICATION
Guide Bore
7.950 – 7.976 mm
(0.313 – 0.314 on.)
Stem to Guide Clearance
0.0254 – 0.0762 mm
(0.001 – 0.003 in.)
Service Limit (rocking
method)
0.4318 mm
(0.017 in.)
VALVE SPRINGS
Free Length
49.962 mm
(1.967 in.)
Spring Tension
valve closed
378 N @ 41.66 mm
(85 lbs. @ 1.64 in.)
valve open
890 N @ 30.89 mm
(200 lbs. @ 1.212 in.)
Number of Coils
6.5
Installed Height
41.66 mm
(1.64 in.)
Wire Diameter
4.50 mm
(0.177 in.)
HYDRAULIC TAPPETS
Body Diameter
22.949 – 22.962 mm
(0.9035 – 0.9040 in.)
Clearance (to bore)
0.0279 – 0.0610 mm
(0.0011 – 0.0024 in.)
Dry Lash
1.524 – 5.334 mm
(0.060 – 0.210 in.)
Push Rod Length
175.64 – 176.15 mm
(6.915 – 6.935 in.)
OIL PRESSURE
Curb Idle (Min.*)
41.4 kPa (6 psi)
@ 3000 rpm
207 – 552 kPa
(30 – 80 psi)
Oil Pressure Bypass
Valve
Setting
62 – 103 kPa
(9 – 15 psi)
DESCRIPTION
SPECIFICATION
Switch Actuating
Pressure
34.5 – 48.3 kPa
(5 – 7 psi)
* If oil pressure is zero at curb idle, DO NOT RUN
ENGINE.
OIL PUMP
Clearance over Rotors
(Max.)
0.0381 mm
(0.0015 in.)
Inner Rotor Thickness
(Min.)
20.955 mm
(0.825 in.)
Outer Rotor Clearance
(Max.)
0.3556 mm
(0.014 in.)
Outer Rotor Diameter
(Min.)
62.7126 mm
(2.469 in.)
Outer Rotor Thickness
(Min.)
20.955 mm
(0.825 in.)
Tip Clearance between
Rotors
(Max.)
0.2032 mm
(0.008 in.)
PISTONS
Clearance at Top of Skirt
0.013 – 0.038 mm
(0.0005 – 0.0015 in.)
Land Clearance (Diam.)
0.635 – 1.016 mm
(0.025 – 0.040 in.)
Piston Length
86.360 mm (3.40 in.)
Piston Ring Groove
Depth
Groove #1&2
4.572 – 4.826 mm
(0.180 – 0.190 in.)
Groove #3
3.810 – 4.064 mm
(0.150 – 0.160 in.)
Weight
592.6 – 596.6 grams
(20.90 – 21.04 oz.)
R1
ENGINE 5.2L INTERNATIONAL
9a - 65
ENGINE 5.2L INTERNATIONAL (Continued)
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