1997-2004 Dodge Dakota Service & Repair Manual (Spanish)

ENGINE page page page page DESCRIPTION AND OPERATION ENGINE ................................. 2 LUBRICATION SYSTEM ..................... 2 EXHAUST MANIFOLD ...................... 3 INTAKE MANIFOLD ........................ 3 CYLINDER HEAD.......................... 3 CRANKSHAFT ............................ 3 CRANKSHAFT MAIN BEARINGS .............. 5 CRANKSHAFT OIL SEALS ................... 5 DIAGNOSIS AND TESTING ENGINE DIAGNOSIS—INTRODUCTION......... 6 SERVICE DIAGNOSIS—PERFORMANCE ....... 6 SERVICE DIAGNOSIS—MECHANICAL ......... 8 SERVICE DIAGNOSIS—LUBRICATION ......... 9 INTAKE MANIFOLD LEAKAGE DIAGNOSIS ...... 9 CYLINDER COMPRESSION PRESSURE TEST . . . 9 CYLINDER HEAD GASKET FAILURE DIAGNOSIS ........................... 10 CYLINDER COMBUSTION PRESSURE LEAKAGE TEST ........................ 10 ENGINE OIL LEAK INSPECTION ............. 11 REAR SEAL AREA LEAKS—INSPECTION ...... 12 HYDRAULIC TAPPETS..................... 12 ENGINE OIL PRESSURE ................... 13 SERVICE PROCEDURES FORM-IN-PLACE GASKETS ................. 14 ENGINE OIL............................. 14 REPAIR DAMAGED OR WORN THREADS ...... 16 CYLINDER BORE—HONING ................ 16 HYDROSTATIC LOCK ..................... 17 VALVE TIMING ........................... 17 VALVE, GUIDE AND SEAL .................. 17 PISTON—FITTING ........................ 19 PISTON RING—FITTING ................... 20 CONNECTING ROD BEARINGS—FITTING ..... 22 CRANKSHAFT MAIN BEARINGS—FITTING ..... 25 REMOVAL AND INSTALLATION ENGINE MOUNTS—FRONT ................. 28 ENGINE REAR SUPPORT .................. 29 ENGINE ................................ 29 INTAKE MANIFOLD ....................... 31 EXHAUST MANIFOLD ..................... 33 CYLINDER HEAD COVER .................. 33 ROCKER ARMS AND PUSH RODS ........... 34 VALVE SPRING AND SEAL ................. 35 CYLINDER HEAD......................... 36 HYDRAULIC TAPPETS..................... 38 VIBRATION DAMPER ...................... 39 TIMING CASE COVER OIL SEAL ............. 39 TIMING CASE COVER ..................... 40 TIMING CHAIN AND SPROCKETS ............ 40 CAMSHAFT ............................. 42 CAMSHAFT PIN REPLACEMENT ............. 43 CAMSHAFT BEARINGS .................... 45 CRANKSHAFT MAIN BEARINGS ............. 45 OIL PAN ................................ 47 OIL PUMP .............................. 48 PISTON AND CONNECTING ROD ............ 49 REAR MAIN OIL SEAL ..................... 50 DISASSEMBLY AND ASSEMBLY CYLINDER HEAD......................... 51 CLEANING AND INSPECTION ROCKER ARMS AND PUSH RODS ........... 51 HYDRAULIC TAPPETS..................... 51 ENGINE CYLINDER HEAD .................. 52 CYLINDER BLOCK........................ 52 INTAKE MANIFOLD ....................... 52 EXHAUST MANIFOLD ..................... 53 SPECIFICATIONS 2.5L ENGINE SPECIFICATIONS .............. 53 SPECIFICATIONS—TORQUE ................ 56 SPECIAL TOOLS 2.5L ENGINE ............................ 57

• • • • Fig. 1 Engine Firing Order Fig. 2 Build Date Code Location 1 – NO. 4 CYLINDER 2 – NO. 3 CYLINDER 3 – DAY 4 – MONTH 5 – YEAR 6 – MACHINED SURFACE

Oil Lubrication System—2.5L Engine

1 – CAM/CRANK MAIN GALLERY (5) 2 – TAPPET GALLERY 3 – TAPPET GALLERY 4 – CAMSHAFT BEARING 5 – NUMBER 1 CAMSHAFT BEARING JOURNAL 6 – CAMSHAFT SPROCKET 7 – TAPPET GALLERY Fig. 3 Cylinder Head—2.5L Engine 1 – BRIDGE 2 – PIVOT ASM. 3 – ROCKER ARM 4 – CYLINDER HEAD 5 – HEAD GASKET 6 – PUSH ROD Fig. 4 Crankshaft 3.9L Engine 1 – MAIN BEARING JOURNALS 2 – COUNTER BALANCE WEIGHTS Fig. 5 Main Bearing Orientation

• • • • CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary. 2. Corroded or loose battery connections. 2. Clean and tighten battery connections. Apply a coat of light mineral grease to the terminals. 3. Faulty starter. 3. Refer to Group 8A, Battery/ Starter/ Charging System Diagnostics. 4. Moisture on ignition wires and distributor cap. 4. Wipe wires and cap clean and dry. 5. Faulty ignition cables. 5. Replace as necessary. 6. Faulty coil or control unit. 6. Refer to Group 8D, Ignition System. 7. Incorrect spark plug gap. 7. Refer to Group 8D, Ignition System. 8. Incorrect ignition timing. 8. Refer to Group 8D, Ignition System. 9. Dirt or water in fuel system. 9. Clean system and replace fuel filter. 10. Faulty fuel pump, relay or wiring. 10. Refer to Group 14, Fuel System. ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low. 1. Refer to Group 14, Fuel System. 2. Idle mixture to lean or to rich. 2. Refer to Group 14, Fuel System. 3. Vacuum leak. 3. Inspect intake manifold and vacuum hoses, repair or replace as necessary. 4. Worn or burned distributor rotor. 4. Replace distributor rotor. 5. Incorrect ignition wiring. 5. Install correct wiring. 6. Faulty coil. 6. Refer to Group 8D, Ignition System. 7. EGR valve leaking. 7. Refer to Group 25, Emissions Control System. 8. Incorrect cam timing. 8. Refer to Valve Timing in this section.

CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Incorrect ignition timing. 1. Refer to Group 8D, Ignition System. 2. Worn or burned distributor rotor. 2. Replace distributor rotor. 3. Worn distributor shaft. 3. Refer to Group 8D, Ignition System. 4. Dirty or incorrectly gapped spark plugs. 4. Refer to Group 8D, Ignition System. 5. Dirt or water in fuel system. 5. Clean system and replace fuel filter. 6. Faulty fuel pump. 6. Refer to Group 14, Fuel System. 7. Blown cylinder head gasket. 7. Replace cylinder head gasket. 8. Low compression. 8. Test compression, repair as necessary. 9. Burned, warped or pitted valves. 9. Replace as necessary. 10. Plugged or restricted exhaust system. 10. Inspect and replace as necessary. 11. Faulty ignition cables. 11. Replace as necessary. 12. Faulty coil. 12. Refer to Group 8D, Ignition System. 13. Incorrect cam timing. 13. Refer to Valve Timing in this section. ENGINE MISSES ON ACCELERATION 1. Spark plugs dirty or incorrectly gapped. 1. Refer to Group 8D, Ignition System. 2. Incorrect ignition timing. 2. Refer to Group 8D, Ignition System. 3. Dirt in fuel system. 3. Clean fuel system. 4. Burned, warped or pitted valves. 4. Replcae as necessary. 5. Faulty coil. 5. Refer to Group 8D, Ignition System. 6. Incorrect cam timing. 6. Refer to Valve Timing in this section. ENGINE MISSES AT HIGH SPEED 1. Spark plugs dirty or incorrectly gapped. 1. Refer to Group 8D, Ignition System. 2. Worn Distributor Shaft. 2. Refer to Group 8D, Ignition System. 3. Worn or burned distributor rotor. 3. Replace distributor rotor. 4. Faulty coil. 4. Refer to Group 8D, Ignition System. 5. Incorrect ignition timing. 5. Refer to Group 8D, Ignition System. 6. Dirt or water in fuel system. 6. Clean system and replace fuel filter. 7. Incorrect cam timing. 7. Refer to Valve Timing in this section.

CONDITION POSSIBLE CAUSES CORRECTIONS NOISY VALVES 1. High or low oil level in crankcase. 1. Refer to Group 0, Lubrication and Maintenance. 2. Thin or diluted oil. 2. Change oil and filter. 3. Low oil pressure. 3. Check oil pump, if Ok, check rod and main bearings for excessive wear. 4. Dirt in lash adjusters. 4. Clean lash adjusters. 5. Bent push rods. 5. Replace as necessary. 6. Worn rocker arms. 6. Replace as necessary. 7. Worn tappets 7. Replace as necessary. 8. Worn valve guides. 8. Refer to Valve Service in this section. 9. Excessive runout of valve seats on valve faces. 9. Service valves and valve seats. Refer to Valve Service in this section. CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Refer to Group 0, Lubrication and maintenance. 2. Low oil pressure. 2. Refer to Group 0, Lubrication and maintenance. 3. Thin or diluted oil. 3. Change oil and filter. 4. Excessive bearing clearance. 4. Replace as necessary. 5. Connecting rod journal out-of-round. 5. Service or replace crankshaft. 6. Misaligned connecting rods. 6. Replace bent connecting rods. MAIN BEARING NOISE 1. Insufficient oil supply. 1. Refer to Group 0, Lubrication and maintenance. 2. Low oil pressure. 2. Refer to Group 0, Lubrication and maintenance. 3. Thin or diluted oil. 3. Change oil and filter. 4. Excessive bearing clearance. 4. Replace as necessary. 5. Excessive end play. 5. Check No. 3 main bearing for wear on flanges. 6. Crankshaft journal out-of round. 6. Service or replace crankshaft. 7. Loose flywheel or torque converter. 7. Tighten to correct torque

CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. 1. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or porous metal parts. (b) Tighten fasteners, Repair or replace metal parts. 2. Crankshaft rear seal 2. Replace as necessary. 3. Crankshaft seal flange. Scratched, nicked or grooved. 3. Polish or replace crankshaft. 4. Oil pan flange cracked. 4. Replace oil pan. 5. Timing chain cover seal, damaged or misaligned. 5. Replace seal. 6. Scratched or damaged vibration damper hub. 6. Polish or replace damper. OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level. 2. Faulty oil pressure sending unit. 2. Replace sending unit. 3. Low oil pressure. 3. Check pump and bearing clearance. 4. Clogged oil filter. 4. Replace oil filter. 5. Worn oil pump. 5. Replace as necessary. 6. Thin or diluted oil. 6. Change oil and filter. 7. Excessive bearing clearance. 7. Replace as necessary. 8. Oil pump relief valve stuck. 8. Clean or replace relief valve. 9. Oil pump suction tube loose or damaged. 9. Replace as necessary. OIL PUMPING AT RINGS; SPARK PLUGS FOULING 1. Worn or damaged rings. 1. Hone cylinder bores and replace rings. 2. Carbon in oil ring slots. 2. Replace rings. 3. Incorrect ring size installed. 3. Replace rings. 4. Worn valve guides. 4. Ream guides and replace valves. 5. Leaking intake gasket. 5. Replace intake gaskets. 6. Leaking valve guide seals. 6. Replace valve guide seals. 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.

• • • • • • • • • WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRES- SURE CAP REMOVED. WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCES- SIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRES- SURE TO EXCEED 138 kPa (20 psi). • • •

1997-2004 Dodge Dakota Service & Repair Manual (Spanish)

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