Dodge Dakota (R1). Manual — part 509
SPECIFICATIONS
5.9L ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION
SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type
90° V-8 OHV
Bore and Stroke
101.6 x 90.9 mm
(4.00 x 3.58 in.)
Displacement
5.9L (360 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
Cylinder Head
Cast Iron
Crankshaft
Nodular Iron
Camshaft
Nodular Cast Iron
Pistons
Aluminum Alloy w/strut
Connecting Rods
Forged Steel
Compression Pressure
689.5 kPa (100 psi)
(Min.)
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.)
DESCRIPTION
SPECIFICATION
Bearing Journal Diameter
No. 1
50.723 – 50.775 mm
(1.997 – 1.999 in.)
No. 2
50.317 – 50.368 mm
(1.981 – 1.983 in.)
No. 3
49.936 – 49.987 mm
(1.966 – 1.968 in.)
No. 4
49.53 – 49.581 mm
(1.950 – 1.952 in.)
No. 5
39.611 – 39.662 mm
(1.5595 – 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.)
Camshaft 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.)
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.)
Main Bearing Journal
Diameter
71.361 – 71.387 mm
(2.8095 – 2.8105 in.)
Out of Round (Max.)
0.127 mm (0.001 in.)
Taper (Max.)
0.0254 mm (0.001 in.)
Bearing Clearance
9 - 224
ENGINE 5.9L
AN
ENGINE 5.9L (Continued)
DESCRIPTION
SPECIFICATION
Journal #1
0.013 – 0.038 mm
(0.0005 – 0.0015 in.)
Journals # 2 - 5
0.013 – 0.051 mm
(0.0005 – 0.002 in.)
Service Limit
Journal #1
0.0381 mm (0.0015 in.)
Journals #2-5
0.064 mm (0.0025 in.)
Crankshaft 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
101.60 – 101.65 mm
(4.000 – 4.002 in.)
Out of Round (Max.)
.0254 mm (0.001 in.)
Taper (Max.)
.0254 mm (0.001 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 AND VALVES
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°
DESCRIPTION
SPECIFICATION
Head Diameter
Intake
47.752 mm (1.88 in.)
Exhaust
41.072 (1.617 in.)
Length (Overall)
Intake
126.21 – 126.85 mm
(4.969 – 4.994 in.)
Exhaust
126.44 – 127.30 mm
(4.978 – 5.012 in.)
Lift (@ zero lash)
Intake
10.414 mm (0.410 in.)
Exhaust
10.592 mm (0.417 in.)
Stem Diameter
Intake
9.449 – 9.474 mm
(0.372 – 0.373 in.)
Exhaust
9.423 – 9.449 mm
(0.371 – 0.372 in.)
Guide Bore
9.500 – 9.525 mm
(0.374 – 0.375 on.)
Stem to Guide Clearance
Intake
0.0254 – 0.0762 mm
(0.001 – 0..003 in.)
Exhaust
0.0508 – 0.1016 mm
(0.002 – 0.004 in.)
Service Limit
0.4318 (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
6.8
Installed Height
41.66 mm (1.64 in.)
Wire Diameter
4.50 mm (0.177 in.)
AN
ENGINE 5.9L
9 - 225
ENGINE 5.9L (Continued)
DESCRIPTION
SPECIFICATION
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)
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.)
0.1016 mm (0.004 in.)
Cover Out of Flat (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.)
Diameter (Min.)
62.7126 mm (2.469 in.)
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.)
0.508 – 0.660 mm
(0.020 – 0.026 in.)
DESCRIPTION
SPECIFICATION
Piston Length
81.03 mm (3.19 in.)
Piston Ring Groove
Depth
Groove #1&2
4.761 – 4.912 mm
(0.187 – 0.193 in.)
Groove #3
3.996 – 4.177 mm
(0.157 – 0.164 in.)
Weight
582 – 586 grams
(20.53 – 20.67 oz.)
PISTON PINS
Clearance in Piston
0.006 – 0.019 mm
(0.00023 – 0.00074 in.)
Diameter
25.007 – 25.015 mm
(0.9845 – 0.9848 in.)
End Play
NONE
Length
67.8 – 68.3 mm
(2.67 – 2.69 in.)
PISTON RINGS
Ring Gap
Compression Ring (Top)
0.30 – 0.55 mm
(0.012 – 0.022 in.)
Compression Ring (2nd)
0.55 – 0.80 mm
(0.022 – 0.031 in.)
Oil Control (Steel Rails)
0.381 – 1.397 mm
(0.015 – 0.055 in.)
Ring Side Clearance
Compression Rings
0.040 – 0.085 mm
(0.0016 – 0.0033 in.)
Oil Ring (Steel Rails)
0.05 – 0.21 mm
(0.002 – 0.008 in.)
Ring Width
Compression rings
1.530 – 1.555 mm
(0.060 – 0.061 in.)
Oil Ring (Steel Rails) –
Max.
0.447 –0.473 mm
(0.018 – 0.019 in.)
9 - 226
ENGINE 5.9L
AN
ENGINE 5.9L (Continued)
DESCRIPTION
SPECIFICATION
VALVE TIMING
Exhaust Valve
Closes (ATDC)
33°
Opens (BBDC)
56°
Duration
269°
Intake Valve
Closes (ATDC)
62°
Opens (BBDC)
7°
Duration
249°
Valve Overlap
41°
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
OS-US
Item
Identification
Location of
Identification
U/S
Crankshaft
R or M M-2-3
ect.
Milled flat on
.025 MM
(indicating No.
2 &
No. three
(.001 in.)
3 main
bearing
crankshaft
journal) and/or
counterweight.
R-1-4 ect.
(indicating
No. 1 &
4 connecting
rod
journal)
O/S
Cylinder
A
Following
.508 mm
Bores
engine serial
(.020 in.)
number.
O/S
Tappets
L
3/8
9
.203 mm
diamound
(.008 in.)
-shaped
stamp Top
pad
— Front of
engine and
flat
ground on
outside
surface
OS-US
Item
Identification
Location of
Identification
of each O/S
tappet bore.
O/S
Valve
Stems
X
Milled pad
.127 mm
adjacent to
two
(.005 in.)
3/8
9
tapped
holes on
each
end of
cylinder
head.
TORQUE
TORQUE CHART 5.9L ENGINE
DESCRIPTION
N·m
Ft.
In.
Lbs.
Lbs.
Camshaft Sprocket—Bolt
68
50
—
Camshaft Thrust Plate—Bolts
24
—
210
Timing Chain Case Cover—
Bolts
41
30
—
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 to
Block—
41
30
—
Bolts (4WD)
Exhaust Manifold to Cylinder
Head—
34
25
—
Bolts/Nuts
Flywheel—Bolts
75
55
—
Front Insulator—Through
bolt/nut
95
70
—
Front Insulator to Support
Bracket
—Stud Nut (4WD)
41
30
—
—Through Bolt/Nut (4WD)
102
75
—
AN
ENGINE 5.9L
9 - 227
ENGINE 5.9L (Continued)
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