Dodge Dakota (R1). Manual — part 534
OIL PUMP PRESSURE RELIEF
VALVE
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(3) Remove the relief valve snap ring.
(4) Remove the relief valve cap, spring, and
plunger (Fig. 74).
(5) Check the relief valve spring length. Relief
valve spring free length is 57.5mm (2.263 in.). If
spring length is less or spring is distorted it must be
replaced.
(6) Check the plunger for scoring, replace if neces-
sary.
INSTALLATION
(1) Thoroughly clean all components and relief
valve pocket in cylinder block.
(2) Fit plunger, spring and cap into block.
(3) Compress spring and install the snap ring.
Ensure the snap ring is completely seated in groove.
(4) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION)
(5) Connect the negative battery cable.
OIL FILTER ADAPTER /
COOLER
REMOVAL
(1) Raise the vehicle on the hoist.
(2) Remove the right front wheel and tire assem-
bly.
(3) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE - STANDARD PROCEDURE).
(4) Working through the right wheel well, position
the splash shield out of the way and remove the oil
filter adapter and cooler retaining bolt.
(5) Remove the oil filter and adapter from the
vehicle.
(6) Remove the upper coolant supply hose from the
cooler assembly. (Fig. 75).
(7) Position the cooler assembly and remove the
remaining coolant hose from the cooler assembly.
(8) Remove the oil cooler from the vehicle.
INSTALLATION
CAUTION: There are two o-ring seals associated
with these components, one is located between the
engine block and oil cooler the other between the
cooler and adapter. Use petroleum jelly to hold
these seals in position during installation. If either
of these seals are not positioned correctly a oil leak
will result.
(1) Position the oil cooler and install the coolant
hoses.
Fig. 73 Checking Rotor Clearance
Fig. 74 Oil Pressure Relief Valve
9a - 54
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
OIL PUMP (Continued)
(2) Install the oil filter and adapter on the oil
cooler base. Torque the bolt to 46.6 N·m (34 ft. lbs.).
(3) Install the right front wheel and tire assembly.
(4) Lower the vehicle on the hoist.
(5) Fill the cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
OIL PAN
REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise the vehicle on hoist.
(3) Drain the oil from the crankcase.
(4) Remove the front skidplate from the vehicle.
(5) Remove the oil pan lower cover bolts.
(6) Remove the bolts from oil pan. Remove the 6
bolts that are on the inside of the oil pan.
(7) Remove the oil pan.
INSTALLATION
(1) Remove all gasket material from cylinder block.
Be careful not gouge or scratch aluminum pan seal-
ing surface.
(2)
Apply a continuous 3 mm bead of Silicone
Sealer to oil pan, install within 10 minutes. Install
the oil pan.
(3) Install the inside oil pan bolts. Torque bolts to
13 N·m (115 in. lbs.).
(4) Torque the smaller oil pan bolts to 13 N·m (115
in. lbs.). Torque the larger oil pan bolts to 25 N·m (18
ft. lbs.).
(5) Install the oil drain plug. Torque to 33 N·m (25
ft. lbs).
(6) Install the front skidplate.
(7) Lower the vehicle from hoist.
(8) Fill engine with proper amount of oil.
(9) Connect the negative battery cable.
ENGINE MOUNT RIGHT SIDE
REMOVAL
(1) Disconnect the negative battery cable.
(2) Install the engine bridge fixture (Fig. 76). Sup-
port the engine assembly.
(3) Raise the vehicle on the hoist.
(4) Remove the engine mount through bolt nut. Do
not remove the bolt at this time.
(5) Remove the (2) engine mount insulator retain-
ing nuts (Fig. 77).
(6) Remove the oil filter adaptor retaining bolt.
Remove the oil filter and adaptor from the vehicle.
(7) Lower the vehicle from the hoist.
(8) Raise the right side of the engine enough to
remove the engine mount through bolt and insulator
from the vehicle.
INSTALLATION
(1) Position the engine mount and install the
engine mount through bolt. Leave loose at this time.
Fig. 75 Oil Cooler
1 - OIL COOLER
Fig. 76 Engine Bridge Fixture
1 - ENGINE BRIDGE FIXTURE
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 55
OIL FILTER ADAPTER / COOLER (Continued)
(2) Lower the engine assembly. Remove the engine
bridge fixture.
(3) Raise the vehicle on the hoist.
(4) Install the oil filter and adaptor. Torque the oil
filter adaptor bolt to 50 N·m (37 ft. lbs.).
(5) Install the (2) engine mount insulator retaining
nuts (Fig. 77). Torque the nuts to 65 N·m (48 ft. lbs.).
(6) Torque the engine mount through bolt to 65
N·m (48 ft. lbs.).
(7) Connect the negative battery cable.
ENGINE MOUNT LEFT SIDE
REMOVAL
(1) Disconnect the negative battery cable.
(2) Install the engine bridge fixture (Fig. 76). Sup-
port the engine assembly.
(3) Raise the vehicle on the hoist.
(4) Remove the engine mount through bolt nut. Do
not remove the bolt at this time.
(5) Remove the (2) engine mount insulator retain-
ing nuts (Fig. 78).
(6) Lower the vehicle on the hoist.
(7) Raise the left side of the engine enough to
remove the engine mount through bolt and insulator
from the vehicle.
INSTALLATION
(1) Position the engine mount and install the
engine mount through bolt. Leave loose at this time.
(2) Lower the engine assembly. Remove the engine
bridge fixure.
(3) Raise the vehicle on the hoist.
(4) Install the (2) engine mount insulator retaining
nuts (Fig. 78). Torque the nuts to 65 N·m (48 ft. lbs.).
(5) Torque the engine mount through bolt to 65
N·m (48 ft. lbs.).
(6) Connect the negative battery cable.
TIMING GEAR COVER OIL
SEAL
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
CAUTION: Use care when removing the old seal. Be
sure not to damage the timing gear cover.
(3) Pry out the old seal.
Fig. 77 Right Engine Mount Retaining Nuts
1 - STARTER MOTOR HEATSHIELD
2 - TURBOCHARGER OIL RETURN LINE
3 - RIGHT ENGINE MOUNT RETAINING NUTS
4 - STARTER MOTOR SUPPORT BRACKET
5 - STARTER MOTOR
Fig. 78 Left Engine Mount Retaining Nuts
1 - ENGINE MOUNT RETAINING NUTS
2 - POWER STEERING PUMP RETAINING NUTS
3 - ENGINE MOUNT BRACKET RETAINING BOLTS
4 - POWER STEERING PUMP
9a - 56
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
ENGINE MOUNT RIGHT SIDE (Continued)
INSTALLATION
Remove the oil seal ring. The seating diameter
must be 68.000 - 68.030 mm.
(1) Install
the
new
seal
using
special
tool
VM.1015A (Fig. 79).
(2) Install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(3) Connect the negative battery cable.
TIMING GEAR COVER
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the fan and set fan inside fan shroud
then remove fan shroud and fan as an assembly.
(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(4) Remove the vibration damper nut.
(5) Install special tool VM.1000-A to remove the
vibration damper.
(6) Remove the fan pulley.
NOTE: The idler pulley bolt has left hand thread.
(7) Remove the idler pulley and bracket.
(8) Remove the automatic belt tensioner.
(9) Remove the Power steering pump pulley.
(10) Remove the timing gear retaining bolts and
cover.
INSTALLATION
(1) Be sure the mating surfaces of the gear case
cover and the cylinder block are clean and free from
burrs.
(2) Apply a continuous 3 mm bead of Silicone
Sealer (Fig. 80) to timing cover, install within 10
minutes, tighten bolts to 10.3 N·m (91 in. lbs.).
(3) Install Power steering pump pulley. Torque
bolts to 166 N·m.
(4) Install the automatic belt tensioner.
NOTE: The idler pulley has left hand thread.
(5) Install the idler pulley. Torque nut to 40 N·m
(29 ft. lbs.).
(6) Install the fan pulley. Torque bolts to 56 N·m
(41 ft. lbs.).
(7) Install the vibration damper, torque nut to 196
N·m (147 ft. lbs.).
(8) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(9) Install the fan and fan shroud.
(10) Connect the negative battery cable.
Fig. 79 Timing Gear Cover Oil Seal
Fig. 80 Front Cover Sealer Location
1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 57
TIMING GEAR COVER OIL SEAL (Continued)
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