Dodge Dakota (R1). Manual — part 456
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopar
t
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed.
Never use the following to clean gasket surfaces:
• Metal scraper
• Abrasive pad or paper to clean cylinder block
and head
• High speed power tool with an abrasive pad or a
wire brush (Fig. 5)
Only use the following for cleaning gasket surfaces:
• Solvent or a commercially available gasket
remover
• Plastic or wood scraper (Fig. 5)
• Drill motor with 3M Roloc™ Bristle Disc (white
or yellow) (Fig. 5)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
REMOVAL
(1) Disconnect the battery cables. Remove the bat-
tery.
(2) Mark the hinge locations on the hood panel for
alignment reference during installation. Remove the
engine compartment lamp. Remove the hood.
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(3) Drain the coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove the air cleaner assembly, air in-let
hose and resonator assembly (Fig. 6).
(5) Recover refrigerant (if equipped with A/C).(Re-
fer to 24 - HEATING & AIR CONDITIONING/
PLUMBING
-
24
-
HEATING
&
AIR
CONDITIONING).
(6) Remove the radiator lower hose.
Fig. 5 PROPER TOOL USAGE FOR SURFACE
PREPARATION
1 - ABRASIVE PAD
2 - 3M ROLOC™ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
Fig. 6 Air Cleaner and Resonator Removal and
Installation
1 - AIR CLEANER ASSEMBLY
2 - NUT AND WASHER
3 - RESONATOR ASSEMBLY
4 - AIR INLET HOSE
9 - 12
ENGINE 2.5L
AN
ENGINE 2.5L (Continued)
(7) Remove the radiator upper hose and coolant
recovery hose (Fig. 7).
(8) Remove the fan shroud (Fig. 7).
(9) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL) and condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C
CONDENSER
-
REMOVAL)
(if
equipped with air conditioning).
(10) Remove fan assembly and install a 5/16 x 1/2-
inch SAE capscrew through fan pulley into water
pump flange. This will maintain the pulley and
water pump in alignment when crankshaft is rotated.
(11) Disconnect the heater hoses.
(12) Disconnect the throttle cable, speed control
cable
(if
equipped)
and
transmission
cable
(if
equipped).
(13) Disconnect the body ground at the firewall.
(14) Disconnect the wires from the starter motor
solenoid.
(15) Disconnect all fuel injection harness connec-
tions.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT
PRESSURE
(EVEN
WITH
THE
ENGINE
TURNED OFF). BEFORE DISCONNECTING FUEL
LINES, THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(16) Perform
fuel
pressure
release
procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(17) Disconnect the quick-connect fuel line at the
fuel rail (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/QUICK CONNECT FITTING - STANDARD
PROCEDURE).
(18) Disconnect suction/discharge hose from A/C
compressor and cap off ports to prevent intrusion of
foreign material or refrigerant oil loss.
(19) Remove the power brake vacuum check valve
from the booster, if equipped.
(20) If equipped with power steering:
(a) Disconnect the power steering hoses from the
fittings at the steering gear.
(b) Drain the pump reservoir.
(c) Cap the fittings on the hoses and steering
gear to prevent foreign material from entering the
system.
(21) Identify, tag and disconnect all necessary wire
connectors and vacuum hoses.
(22) Raise the vehicle.
(23) Remove the oil filter.
(24) Remove the starter motor(Refer to 8 - ELEC-
TRICAL/STARTING/STARTER MOTOR - REMOV-
AL).
(25) Disconnect the exhaust pipe from the exhaust
manifold.
(26) Remove the flywheel housing access cover.
(27) Remove the upper flywheel and converter
housing bolts and loosen the bottom bolts.
(28) Remove the engine support cushion-to-engine
compartment bracket bolts.
(29) Remove the engine shock damper bracket
from the sill.
(30) Lower the vehicle.
(31) Attach a lifting device to the engine.
(32) Raise the engine slightly off the front sup-
ports.
(33) Place a support stand under the converter or
flywheel housing.
(34) Lift the engine out of the engine compartment
and install on an engine stand.
(35) Install the oil filter to keep foreign material
out of the engine.
INSTALLATION
(1) Remove the oil filter.
(2) Lift the engine off the stand and lower it into
the engine compartment. For easier installation, it
may be useful to remove the engine support cushions
from the engine support brackets as an aide for
alignment of the engine-to-transmission.
(3) Insert the transmission shaft into the clutch
spline. (M/T models)
(4) Align the flywheel housing with the engine.
(5) Install and tighten the flywheel housing lower
bolts.
(6) Install
the
engine
support
cushions
(if
removed).
Fig. 7 Upper Radiator Hose, Coolant Recovery Hose
& Fan Shroud
1 - UPPER RADIATOR HOSE
2 - FAN SHROUD
3 - COOLANT RECOVERY HOSE
AN
ENGINE 2.5L
9 - 13
ENGINE 2.5L (Continued)
(7) Lower the engine and engine support cushions
onto the engine compartment brackets.
(8) Remove the engine lifting device.
(9) Raise the vehicle.
(10) Install the converter-housing access cover.
(11) Install the exhaust pipe support.
(12) Install the starter motor (Refer to 8 - ELEC-
TRICAL/STARTING/STARTER MOTOR - INSTAL-
LATION).
(13) Tighten the engine support cushion through-
bolt nuts.
(14) Connect the exhaust pipe to the manifold.
(15) Install the oil filter.
(16) Lower the vehicle.
(17) Connect the coolant hoses and tighten the
clamps.
(18) If equipped with power steering:
(a) Remove the protective caps
(b) Connect the hoses to the fittings at the steer-
ing gear. Tighten the nut to 52 N·m (38 ft. lbs.)
torque.
(c) Fill the pump reservoir with fluid.
(19) Remove
the
pulley-to-water
pump
flange
alignment capscrew and install the fan assembly.
(20) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION),condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - INSTALLATION)
(if equipped with air conditioning) and fan shroud.
(21) Connect the radiator hoses.
(22) Connect the oxygen sensor wire connector.
(23) Connect the throttle cable and install the rod.
Connect the transmission and speed control cables (if
equipped)
(24) Connect the fuel supply line to the injector
rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(25) Connect all the vacuum hoses and wire con-
nectors.
(26) Connect suction/discharge hose to compressor
(if equipped).
(27) Fill the power steering reservoir.
(28) Recharge air conditioning (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(29) Connect the battery cables.
(30) Install the resonator assembly, air in-let hose
and air cleaner (Fig. 6).
(31) Install the hood.
(32) Add engine oil and coolant.
(33) Start the engine and inspect for leaks.
(34) Stop the engine and check the fluid levels.
Add fluid, as required.
SPECIFICATIONS
2.5L ENGINE
ENGINE DESCRIPTION
DESCRIPTION
SPECIFICATION
Engine Type
In-line 4 Cylinder
Bore and Stroke
98.4 x 81.0 mm
(3.88 x 3.19 in.)
Displacement
2.5L (150 cu. in.)
Compression Ratio
9.1:1
Compression Pressure
Range
827 to 1,034 kPa
(120 to 150 psi)
Max. Variation Between
Cylinders
206 kPa (30 psi)
Firing Order
1–3–4–2
Lubrication
Pressure Feed–Full Flow
Filtration
Cooling System
Liquid Cooled–Forced
Circulation
Cylinder Block
Cast Iron
Crankshaft
Cast Nodular Iron
Cylinder Head
Cast Iron
Camshaft
Cast Iron
Pistons
Aluminum Alloy
Cylinder Combustion
Cavity
Double Quench
Connecting Rods
Cast Iron
CAMSHAFT
Hydraulic Tappet
Clearance
Zero Lash
Bearing Clearance
0.025 - 0.076 mm
(0.001 - 0.003 in.)
Bearing Journal Diameter
No. 1
51.54 - 51.56 mm
(2.029 - 2.030 in.)
No. 2
51.28 - 51.31 mm
9 - 14
ENGINE 2.5L
AN
ENGINE 2.5L (Continued)
DESCRIPTION
SPECIFICATION
(2.019 - 2.020 in.)
No. 3
51.03 - 51.05 mm
(2.009 - 2.010 in.)
No. 4
50.78 - 50.80 mm
(1.999 - 2.000 in.)
Base Circle Runout
(Max)
0.03 mm
(0.001 in.)
Camshaft Lobe Lift
Exhaust
6.579 mm (0.259 in.)
Intake
6.477 mm (0.255 in.)
Camshaft Duration
Intake
253.3°
Exhaust
259°
VALVES
Valve Lift
Exhaust
10.528 mm (0.4145 in.)
Intake
10.350 mm (0.4075 in.)
Intake Valve Timing
Opens
15.4° (BTDC)
Closes
58° (ABDC)
Duration
253.3°
Exhaust Valve Timing
Opens
52.8° (BBDC)
Closes
26.2° (ATDC)
Duration
259°
Valve Overlap
41.6°
Valve Lenght (Overall)
Intake
124.435 - 125.070 mm
(4.899 - 4.924 in.)
Exhaust
125.120 - 125.755 mm
(4.927 - 4.952 in.)
Valve Stem Diameter
7.899 - 7.925 mm
(0.311 - 0.312 in.)
Stem to Guide Clearance
0.025 - 0.076 mm
(0.001 - 0.003 in.)
ValveFace Angle
Intake
46.5°
DESCRIPTION
SPECIFICATION
Exhaust
46.5°
Valve Head Diameter
Intake
48.387 - 48.641 mm
(1.905 - 1.915 in.)
Exhaust
37.973 - 38.227 mm
(1.495 - 1.505 in.)
Tip Refinishing (Max
Alowable)
0.25 mm (0.010 in.)
VALVE SPRINGS
Free Length (Approx.)
47.65 mm (1.876 in.)
Spring Load
Valve Closed
316 to 351 N @ 41.656
mm
(71 to 79 Lbs. @ 1.64
in.)
Valve Open
898.6 to 969.7 N @
30.89 mm
(202 to 218 Lbs. @ 1.216
in.)
Inside Diameter (Top)
21.0 mm to 21.51 mm
(0.827 to 0.847 in.)
Installed Height
41.656 mm (1.640 in.)
CRANKSHAFT
End Play
0.038 to 0.165 mm
(0.0015 to 0.0065 in.)
Main Bearing Journal
Diameter
63.489 to 63.502 mm
(2.4996 to 2.5001 in.)
Main Bearing Journal
Width
No. 1
27.58 to 27.89 mm
(1.086 to 1.098 in.)
No. 2
32.28 to 32.33 mm
(1.271 to 1.273 in.)
No. 3-4-5
30.02 to 30.18 mm
(1.182 to 1.188 in.)
Main Bearing Clearance
0.03 to 0.06 mm
(0.001 to 0.0025 in.)
Main Bearing Clearance
AN
ENGINE 2.5L
9 - 15
ENGINE 2.5L (Continued)
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