2.5L Engine - VIN P: Other Dodge Dakota II

FUEL PRESSURE RELEASE

COOLING SYSTEM BLEEDING

Fill radiator completely and install pressure cap. Fill reserve/overflow tank to FULL mark. Operate engine until it reaches normal operating temperature. Shut off engine and allow it to cool. Recheck coolant level in reserve/overflow tank as necessary. DO NOT add coolant when engine is hot.

POWER STEERING BLEEDING

1. Fill pump to COLD level on dipstick and let fluid settle for at least 2 minutes. Start engine and let run for a few seconds then turn engine off. Add fluid if necessary. Repeat above procedure until fluid level remains constant after running engine.
2. Raise and support front wheels. Slowly turn steering wheel right and left, lightly contacting wheel stops. Turn wheel at least 20 times. Check fluid level and add if necessary.
3. Lower vehicle, start engine and turn steering wheel slowly from lock to lock. Stop engine, check fluid level and add if necessary. If fluid is extremely foamy or milky looking, allow vehicle to stand a few minutes and repeat bleeding procedure.

Valve Springs

Use Valve Spring Tester (C-647) to test each valve spring. Measure free length of each valve spring. Replace valve springs that do not meet specifications. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

Replace valve stem oil seals if they have deteriorated or whenever valves are serviced. Oil seals are marked INT and EXH for intake and exhaust valves, respectively. Oversize oil seals must be used with valves having .015" (.38 mm) oversize stems.

Valve Guides

Measure diameter of valve guide approximately 3/8" (10 mm) from valve spring side of head, both parallel and at right angle to long axis of head. If difference between measurements exceeds .0025" (.063 mm), or if diameter exceeds specification by .003" (.08 mm), ream valve guide for oversize valve stem. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Reface valve seats after reaming valve guides.

Valve Seats

Reface valve seats to specification. Remove only enough metal to provide smooth finish. Use tapered stones to obtain specified seat width. (Scheme 28) Seat width runout should not exceed.0025" (.063 mm) after refacing. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valves

Reface valves to specification. At least 1/32" (.79 mm) margin must remain after refacing valve. Valve stem tip can be resurfaced and chamfered when worn. DO NOT remove more than .01" (.25 mm). See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Scheme 28

Rocker Arms

Inspect pivot and valve stem contact surfaces of each rocker arm. Replace any rocker arm that is scuffed, pitted, cracked or excessively worn.

Push Rods

Inspect push rods for excessive wear. If wear is excessive because of lack of oil, replace and inspect corresponding valve lifter for excessive wear. Roll push rods on a flat surface to check for straightness. Replace push rod and/or valve lifter, if necessary. If wear exists along length of push rod, inspect cylinder head for obstruction.

Piston Rings

Install piston rings. DO NOT interchange piston rings. Top ring has a Gray scraping surface. Second ring is Black. Ensure ring end gap and side clearance are within specification. Install compression rings with dot(s) on ring surface toward top of piston. Position ring end gaps in specified area. Ring gaps may vary 20 degrees from locations illustrated. (Scheme 29) Also see PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.

Scheme 29

Rod Bearings

1. Inspect bearings for wear or damage. Replace as necessary. Using Plastigage, check bearing clearance. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-97921-S26212757102001051500000) table under ENGINE SPECIFICATIONS. Bearings are available for standard and undersize applications.
2. If necessary, different size upper and lower bearings may be combined to obtain correct oil clearance. See «CRANKSHAFT JOURNAL IDENTIFICATION»(ref-97921-S12729708542001051500000) and «CONNECTING ROD BEARING INSERT APPLICATION»(ref-97921-S39013234712001051500000) tables. Tighten bolts to specification. Check rod side play. Rotate crankshaft to ensure freedom of movement. See «TORQUE SPECIFICATIONS»(ref-97921-S09687572562001051500000) . See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-97921-S10640405992001051500000) table.

Crankshaft & Main Bearings

1. Inspect bearings for damage or wear. Replace as necessary. Using Plastigage, measure bearing clearance. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-97921-S10640405992001051500000) table under ENGINE SPECIFICATIONS. Bearings are available in standard and undersize. If necessary, different size upper and lower bearings may be installed to obtain correct oil clearance. Lubricate bearings before installation. See «MAIN BEARING FITTING CHART (CRANK SHAFT JOURNALS)»(ref-97921-S28704066572001051500000) and «CRANKSHAFT BEARING INSERT APPLICATION»(ref-97921-S36739640542001051500000) tables. CAUTION: If different size bearings are installed, the odd size bearings must all be uniform in location (upper or lower). Never combine bearing inserts that differ by more than .001" (.03 mm).
2. Install upper bearing inserts. Install bearing caps and lower inserts. Tighten bearing caps No. 1, 3, 4 and 5 in 3 stages to specification. Pry crankshaft to front or rear and tighten bolts for cap No. 2 to specification in 3 stages. Rotate crankshaft to ensure freedom of movement after tightening each cap. See «TORQUE SPECIFICATIONS»(ref-97921-S09687572562001051500000) . See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-97921-S10640405992001051500000) table under ENGINE SPECIFICATIONS.

Thrust Bearing

Check crankshaft end play. If end play is not within specification, replace bearing No. 2. If end play is still not within specification, replace crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Cylinder Block

1. Using a dial bore gauge, measure cylinder bore diameter crosswise to cylinder block near top of bore. Repeat measurement at bottom of bore. Subtract smaller diameter from larger diameter to determine taper. Repeat measurements for each cylinder.
2. Repeat measurements with bore gauge rotated 120 degrees. Repeat this step for a total of 3 measurements. Cylinder out-of-round is the difference between measurements. Repeat for each cylinder.
3. Bore and hone cylinders for oversize pistons if taper or out-of-round exceeds specification. See «CYLINDER BLOCK»(ref-97921-S20412315512001051500000) table under ENGINE SPECIFICATIONS. Use 220 grit stones to remove out of round. Run hone up and down evenly to provide a 50-60 degree crosshatch pattern for seating of rings. Use a controlled honing speed of 200-300 RPM. DO NOT use a rigid hone. If deglazing needs to be performed. Hone, using 280 stones, 20-60 strokes depending on bore condition.

CRANKSHAFT JOURNAL IDENTIFICATION

CONNECTING ROD BEARING INSERT APPLICATION

MAIN BEARING FITTING CHART (CRANKSHAFT JOURNALS)

CRANKSHAFT BEARING INSERT APPLICATION

Oil Pressure

Normal oil pressure should be 13 psi (0.9 kg/cm 2 ) at 600 RPM, 25-35 psi (1.8-2.5 kg/cm 2 ) at 800 RPM and 37-75 psi (2.6-5.3 kg/cm 2 ) at 1600 RPM. Oil pressure relief occurs at 75 psi (5.3 kg/cm 2 ).

Scheme 30