Dodge Dakota (R1). Manual — part 501
INSTALLATION
(1) Position the oil pump onto the crankshaft and
install two oil pump retaining bolts.
(2) Position the primary timing chain tensioner
and install the two retaining bolts.
(3) Tighten the oil pump and primary timing chain
tensioner retaining bolts to 28 N·m (250 in. lbs.) in
the sequence shown (Fig. 114).
(4) Install the secondary timing chain tensioners
and timing chains (Refer to 9 - ENGINE/VALVE
TIMING/TIMING BELT/CHAIN AND SPROCKETS -
INSTALLATION).
(5) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(6) Install the pick-up tube and oil pan (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
Fig. 111 Measuring Outer Rotor Clearance in
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 112 Measuring Clearance Between Rotors
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 113 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 114 Oil Pump and Primary Timing Chain
Tightening Sequence
9 - 192
ENGINE 4.7L
AN
OIL PUMP (Continued)
INTAKE MANIFOLD
DESCRIPTION
The intake manifold is made of a composite mate-
rial and features long runners which maximizes low
end torque. The intake manifold uses single plane
sealing which consist of eight individual press in
place port gaskets to prevent leaks. Eight studs and
two bolts are used to fasten the intake to the head.
DIAGNOSIS AND TESTING—INTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove resonator assembly and air inlet hose.
(3) Disconnect throttle and speed control cables.
(4) Disconnect electrical connectors for the follow-
ing components:
• Manifold Absolute Pressure (MAP) Sensor
• Intake Air Temperature (IAT) Sensor
• Throttle Position (TPS) Sensor
• Coolant Temperature (CTS) Sensor
• Idle Air Control (IAC) Motor
(5) Disconnect brake booster hose and positive
crankcase ventilation (PCV) hose.
(6) Disconnect generator electrical connections.
(7) Disconnect air conditioning compressor electri-
cal connections.
(8) Disconnect left and right radio suppressor
straps.
(9) Disconnect and remove ignition coil towers
(Refer to 8 - ELECTRICAL/IGNITION CONTROL/
IGNITION COIL - REMOVAL).
(10) Remove top oil dipstick tube retaining bolt
and ground strap.
(11) Bleed fuel system (Refer to 14 - FUEL SYS-
TEM/FUEL
DELIVERY
-
STANDARD
PROCE-
DURE).
(12) Remove fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
(13) Remove throttle body assembly and mounting
bracket.
(14) Drain cooling system below coolant tempera-
ture level (Refer to 7 - COOLING - STANDARD
PROCEDURE).
(15) Remove the heater hoses from the engine
front cover and the heater core.
(16) Unclip and remove heater hoses and tubes
from intake manifold (Fig. 115).
(17) Remove coolant temperature sensor (Refer to
7 - COOLING/ENGINE/ENGINE COOLANT TEM-
PERATURE SENSO - REMOVAL).
(18) Remove intake manifold retaining fasteners in
reverse order of tightening sequence (Fig. 116).
(19) Remove intake manifold.
CLEANING
NOTE: There is NO approved repair procedure for
the intake manifold. If severe damage is found dur-
ing
inspection,
the
intake
manifold
must
be
replaced.
Before installing the intake manifold thoroughly
clean the mating surfaces. Use a suitable cleaning
solvent, then air dry.
Fig. 115 Heater Hoses and Tubes Removal /
Installation
1 - HEATER HOSES AND TUBES
2 - ROUTING/RETAINING CLIPS
AN
ENGINE 4.7L
9 - 193
INSPECTION
(1) Inspect the intake sealing surface for cracks,
nicks and distortion.
(2) Inspect the intake manifold vacuum hose fit-
tings for looseness or blockage.
(3) Inspect the manifold to throttle body mating
surface for cracks, nicks and distortion.
INSTALLATION
(1) Install intake manifold gaskets.
(2) Position intake manifold.
(3) Install intake manifold retaining bolts and
tighten in sequence shown in (Fig. 117) to 12 N·m
(105 in. lbs.).
(4) Install left and right radio suppressor straps.
(5) Install throttle body assembly.
(6) Install throttle cable bracket.
(7) Connect throttle cable and speed control cable
to throttle body.
(8) Install fuel rail (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL RAIL - INSTALLATION).
(9) Install ignition coil towers (Refer to 8 - ELEC-
TRICAL/IGNITION CONTROL/IGNITION COIL -
INSTALLATION).
(10) Position and install heater hoses and tubes
onto intake manifold.
(11) Install the heater hoses to the heater core and
engine front cover.
(12) Connect electrical connectors for the following
components:
• Manifold Absolute Pressure (MAP) Sensor
• Intake Air Temperature (IAT) Sensor
• Throttle Position (TPS) Sensor
• Coolant Temperature (CTS) Sensor
• Idle Air Control (IAC) Motor
• Ignition coil towers
• Fuel injectors
(13) Install top oil dipstick tube retaining bolt and
ground strap.
(14) Connect generator electrical connections.
(15) Connect Brake booster hose and Positive
crankcase ventilation (PCV) hose.
(16) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(17) Install resonator assembly and air inlet hose.
(18) Connect negative cable to battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds are log style with a pat-
ented flow enhancing design to maximize perfor-
mance. The exhaust manifolds are made of high
silicon molybdenum cast iron. A perforated core
graphite exhaust manifold gasket is used to improve
sealing to the cylinder head. The exhaust manifolds
are covered by a three layer laminated heat shield
for thermal protection and noise reduction. The heat
shields are fastened with a torque prevailing nut
that is backed off slightly to allow for the thermal
expansion of the exhaust manifold.
REMOVAL
RIGHT EXHAUST MANIFOLD
(1) Disconnect negative cable for battery.
(2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
Fig. 116 Intake Manifold Tightening Sequence
Fig. 117 Intake Manifold Tightening Sequence
9 - 194
ENGINE 4.7L
AN
INTAKE MANIFOLD (Continued)
(3) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(4) Remove A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - REMOVAL).
(5) Remove A/C accumulator support bracket fas-
tener.
(6) Drain coolant below heater hose level (Refer to
7 - COOLING - STANDARD PROCEDURE).
(7) Remove heater hoses at engine.
(8) Remove fasteners attaching exhaust manifold
heat shield.
(9) Remove heat shield.
(10) Remove upper exhaust manifold attaching fas-
teners.
(11) Raise vehicle on hoist.
(12) Disconnect exhaust pipe from manifold.
(13) Remove fasteners attaching starter. Move
starter aside.
(14) Remove lower exhaust manifold attaching fas-
teners.
(15) Remove exhaust manifold and gasket (Fig.
118). Manifold is removed from below the engine
compartment.
LEFT EXHAUST MANIFOLD
(1) Disconnect negative cable for battery.
(2) Hoist vehicle.
(3) Disconnect exhaust pipe at manifold.
(4) Lower vehicle.
Fig. 118 Exhaust Manifold—Right
ITEM
DESCRIPTION
TORQUE
ITEM
DESCRIPTION
TORQUE
1
Stud (Qty 2)
25 N·m (18 ft. lbs.)
4
Nut (Qty 2)
8 N·m (72 in. lbs.),
then loosen 45
degrees
2
Bolt (Qty 4)
5
Nut (Qty 2)
3
Stud (Qty 2)
AN
ENGINE 4.7L
9 - 195
EXHAUST MANIFOLD (Continued)
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