Dodge Dakota (R1). Manual — part 529
(39) Install the fuel filter, Tighten bolts to 28 N·m
(250 in. lbs.)
(40) Connect the fuel supply and return lines.
(41) Connect the upper radiator hose.
(42) Connect the negative cable battery.
(43) If equipped with A/C, evacuate and charge the
air conditioning system. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/REFRIGERANT -
STANDARD PROCEDURE).
(44) Fill the cooling system. Check for leaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(45) Operate the engine with the radiator cap off.
Inspect for leaks and continue operating the engine
until the thermostat opens. Add coolant, if required.
NOTE:
After
rebuild
or
cylinder
head
gasket
replacement, the cylinder head must be retorqued
within the first 20,000 km. If individual fiber type
head gaskets were used.
NOTE: The one piece steel type head gasket does
not require, the above mentioned, retorque proce-
dure.
CYLINDER HEAD RE-TORQUE
Within the first 20,000 km (12,000 miles) after
rebuild, retorque the cylinder head bolts as follows:
(Fig. 33) Central bolts A-L: Without slackening the
bolts, following alphabetical order tighten the bolts
through an angle of 15°. Side bolts M1-M2: Without
slackening, tighten M1 then M2 bolts through an
angle of 15°.
HYDRAULIC TAPPETS
DESCRIPTION-OIL PRESSURE
Before disassembling any part of the engine to cor-
rect tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending unit. The pressure should be 50
psi at 3000 RPM.
Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick. The oil level in the pan
should never be above the FULL mark or below the
ADD OIL mark on dipstick. Either of these 2 condi-
tions could be responsible for noisy tappets:
OIL LEVEL HIGH
If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the
engine running, this condition could create foam in
the oil pan. Foam in oil pan would be fed to the
hydraulic tappets by the oil pump causing them to
lose length and allow valves to seat noisily.
OIL LEVEL LOW
Low oil level may allow oil pump to take in air.
When air is fed to the tappets, they lose length which
allows valves to seat noisily. Any leaks on intake side
of oil pump through which air can be drawn will cre-
ate the same tappet action. Check the lubrication
system from the intake strainer to the pump cover,
including the relief valve retainer cap. When tappet
noise is due to aeration, it may be intermittent or
constant, and usually more than 1 tappet will be
noisy. When oil level and leaks have been corrected,
operate the engine at fast idle. Run engine for a suf-
ficient time to allow all of the air inside the tappets
to be bled out.
Fig. 34 Oil Feed Line Retainer
1 - CYLINDER HEAD OIL SUPPLY LINE RETAINING CLIP
2 - EXHAUST MANIFOLD
3 - CYLINDER HEAD OIL SUPPLY LINE
4 - REAR OF CYLINDER HEADS
5 - CYLINDER HEAD COVER
9a - 34
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
CYLINDER HEAD (Continued)
DIAGNOSIS AND TESTING - TAPPET NOISE
(1) To determine source of tappet noise, operate
engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy tappet will cause the affected
spring and/or rocker arm to vibrate or feel rough in
operation.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3) Valve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces-
sive leak down around the unit plunger or by the
plunger partially sticking in the tappet body cylinder.
The tappet should be replaced. A heavy click is
caused by a tappet check valve not seating or by for-
eign particles becoming wedged between the plunger
and the tappet body. This will cause the plunger to
stick in the down position. This heavy click will be
accompanied by excessive clearance between the
valve stem and rocker arm as valve closes. In either
case, tappet assembly should be removed for inspec-
tion and cleaning.
The valve train generates a noise very much like a
light tappet noise during normal operation. Care
must be taken to ensure that tappets are making the
noise. In general, if more than one tappet seems to
be noisy, its probably not the tappets.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Discharge
the
air
conditioning
system,
if
equipped. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/REFRIGERANT
-
STAN-
DARD PROCEDURE).
(3) If equipped with air conditioning, remove the
A/C lines at the compressor and cap.
(4) Remove the A/C line bracket attached to the
cylinder head cover and move the lines away from
the cylinder head.
(5) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(6) Remove the rocker assemblies and push rods.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - REMOVAL). Identify push rods to ensure
installation in original location.
(7) Remove cylinder head, intake manifold, and
exhaust manifold. (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(8) Remove the tappet retainers (Fig. 35).
(9) Slide Hydraulic Tappet Remover/Installer Tool
through opening in block and seat tool firmly in the
head of tappet.
(10) Pull the tappet out of the bore with a twisting
motion. If all tappets are to be removed, identify tap-
pets to ensure installation in original location.
CAUTION: The plunger and tappet bodies are not
interchangeable.
The
plunger
and
valve
must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. DO NOT dis-
assemble a tappet on a dirty work bench.
INSTALLATION
(1) Lubricate the tappets.
(2) Install the tappets and retainers in their origi-
nal positions. Ensure that the oil feed hole in the
side of the tappet body faces up (away from the
crankshaft).
(3) Install the cylinder head, intake manifold, and
exhaust manifold (Refer to 9 - ENGINE/CYLINDER
HEAD - INSTALLATION).
(4) Install the push rods.
(5) Install the rocker arms (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION).
(6) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION).
(7) Connect the negative battery cable.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
Fig. 35 Tappet And Retainer
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 35
HYDRAULIC TAPPETS (Continued)
(8) Start and operate engine. Warm up to normal
operating temperature.
CYLINDER HEAD COVER
REMOVAL
(1) Disconnect the negative battery cable.
WARNING:
DO
NOT
REMOVE
THE
CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) On right hand drive vehicles, drain the cooling
system (Refer to 7 - COOLING/ENGINE - STAN-
DARD PROCEDURE).
(3) Recover
the
air
conditioning
system
if
equipped. Refer to Group 24, Heating and Air Condi-
tioning for the procedure.
(4) Remove the A/C lines at the compressor and
cap all openings. Refer to Group 24, Heating and Air
Conditioning for the procedure. Remove the A/C line
support bracket attached to cylinder head cover, and
move the A/C, vacuum lines away from the cylinder
head.
(5) Remove the generator support brace.
(6) Remove the Crankcase breather hose from the
rear of the valve cover.
(7) Remove the cylinder head cover bolts.
(8) Remove the cylinder head cover.
INSTALLATION
(1) Install the cylinder head cover. Torque the bolts
to 15 N·m (133 in. lbs.).
(2) Connect the crankcase breather hose.
(3) Install the generator suppport brace. Torque
bolt to 27 N·m (20 ft. lbs.) and nut to 11 N·m (8ft.
lbs.).
(4) Install the A/C lines on the compressor and
install the support bracket on the cylinder head
cover. Torque bolt to 7 N·m (62 in. lbs.).
(5) Connect the negative battery cable.
(6) If equipped with A/C, evacuate and charge the
air conditioning system (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/REFRIGERANT -
STANDARD PROCEDURE).
(7) On right hand drive vehicles, fill the cooling
system. Check for leaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(8) Operate the engine with the radiator cap off.
Inspect for leaks and continue operating the engine
until the thermostat opens. Add coolant, if required.
INTAKE/EXHAUST VALVES
AND SEATS
STANDARD PROCEDURE - VALVE SERVICE
This procedure is done with the engine cylinder
head removed from the block.
DISASSEMBLY
(1) Remove the engine cylinder head from the cyl-
inder block (Refer to 9 - ENGINE/CYLINDER HEAD
- REMOVAL).
(2) Use Valve Spring Compressor Tool and com-
press each valve spring.
(3) Remove the valve locks, retainers, and springs.
(4) Use an Arkansas smooth stone or a jewelers
file to remove any burrs on the top of the valve stem,
especially around the groove for the locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
VALVE CLEANING
(1) Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
guides and head.
(2) Clean all grime and gasket material from the
engine cylinder head machined gasket surface.
INSPECTION
(1) Inspect for cracks in the combustion chambers
and valve ports.
(2) Inspect for cracks on the exhaust seat.
(3) Inspect for cracks in the gasket surface at each
coolant passage.
9a - 36
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
HYDRAULIC TAPPETS (Continued)
(4) Inspect valves for burned, cracked or warped
heads.
(5) Inspect for scuffed or bent valve stems.
(6) Replace valves displaying any damage.
(7) Check valve spring height (Fig. 36).
VALVE REFACING
(1) Use a valve refacing machine to reface the
intake and exhaust valves to the specified angle.
(2) After refacing, a margin of at least 4.52-4.49
mm (.178-.177 inch) must remain (Fig. 37). If the
margin is less than 4.49 mm (.177 inch), the valve
must be replaced.
VALVE SEAT REFACING
(1) Install a pilot of the correct size in the valve
guide bore. Reface the valve seat to the specified
angle with a good dressing stone. Remove only
enough metal to provide a smooth finish.
(2) Use tapered stones to obtain the specified seat
width when required.
Fig. 36 Valve Spring Chart
LOAD Kg
HEIGHT mm
STATE
P1
0.00
H1
44.65
FREE LENGTH
P2
32-36
H2
38.60
VALVE CLOSED
P3
89-96
H3
28.20
VALVE OPEN
Fig. 37 Valve Specification
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 37
INTAKE/EXHAUST VALVES AND SEATS (Continued)
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