2000 Dodge Dakota Service & Repair Manual

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

2000 Dodge Dakota Service & Repair Manual

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