2.5L Engine - VIN P: Removal & Installation Dodge Dakota II

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal & Installation (Tab Type Fitting)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97921-S42615508672001051500000). Disconnect negative battery cable. Ensure area around fuel line and disconnect fitting is clean. Place shop towel around fuel line.
2. On two-tab connectors, squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. On single-tab connectors, use screwdriver to pry up pull tab. (Scheme 21) Raise pull tab until it separates from quick-connect fitting. Discard old pull tab. Disconnect quick-connect fitting from fuel line.
3. To install, coat fuel tube nipple with clean 30W engine oil. Insert quick-connect fitting into fuel tube until stop on fuel tube rests against back of quick-connect fitting.
4. On single-tab connectors, obtain NEW pull tab. Push tab down until it locks into quick-connect fitting. On 2-tab connectors, firmly pull on fuel tube and fitting to ensure retainer and quick-connect fitting are locked.

Removal & Installation (Retainer Type Fitting)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97921-S42615508672001051500000). Disconnect negative battery cable. Ensure area around fuel line and disconnect fitting is clean. Place shop towel around fuel line.
2. Pull backward on disconnect fitting while depressing plastic ring into disconnect fitting. (Scheme 22) It may be necessary to use a wrench to depress plastic ring. Separate fuel line from disconnect fitting.
3. To install, ensure plastic ring is in outward position (away from disconnect fitting). If plastic ring is in inward position (toward disconnect fitting), disconnect fitting must be replaced.
4. Lubricate end of fuel line with 30W engine oil. Insert fuel line into disconnect fitting until shoulder on fuel line locks in place.
5. Pull on fuel line and disconnect fitting to ensure fuel line is locked in place. If fuel line is not locked in place, ensure plastic ring is not causing locking retainer to remain in the released position. Reconnect negative battery cable. Start engine and check for leaks.

Scheme 21

Scheme 22

Removal (Cherokee)

1. Remove battery and air cleaner. Remove hood. Drain cooling system. Remove radiator hoses, coolant recovery hose and fan shroud. Disconnect transmission fluid cooler lines (if equipped).
2. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling equipment. Remove A/C condenser (if equipped) and radiator. Remove fan. To maintain pulley and water pump alignment, install a 5/16 x 1/2" bolt through fan pulley into water pump flange.
3. Disconnect heater hoses, throttle linkage, cruise control cable (if equipped) and throttle valve rod. Disconnect wires from starter solenoid, oxygen (HO2S) sensor and all fuel injection harness connections.
4. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97921-S32383386532001051500000) . Disconnect fuel supply and return lines at fuel rail. See «FUEL LINE DISCONNECT FITTINGS»(ref-97921-S32383386532001051500000) . Disconnect TDC sensor wire connector. Remove A/C service valves, and cap compressor ports (if equipped).
5. Remove vacuum check valve from power brake booster. Disconnect power steering hoses at steering gear (if equipped). Drain power steering pump reservoir. Cap power steering hoses and fittings.
6. Tag and disconnect any remaining hoses or electrical connectors. Raise and support vehicle. Disconnect exhaust pipe from exhaust manifold. Remove starter and flywheel cover.
7. On vehicles equipped with automatic transmission, mark converter and flexplate for installation reference. Remove converter-to-flexplate bolts. On all models, remove upper bellhousing bolts and loosen bottom bolts. Remove engine mount bolts.
8. Remove engine shock damper bracket. Lower vehicle. Attach lifting device to engine. Raise engine from front supports. Place support under bellhousing. Remove remaining bellhousing bolts. Remove engine.

Removal (Dakota)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97921-S32383386532001051500000) . Disconnect and remove battery. Scribe hood hinge location on hood for installation reference. Remove hood.
2. Remove air cleaner. Drain cooling system and remove radiator. Discharge A/C system using approved refrigerant recovery/recycling equipment, and remove A/C compressor. Remove fan. To maintain pulley and water pump alignment, install a 5/16 x 1/2" bolt through fan pulley into water pump flange.
3. Disconnect necessary coolant hoses, linkage, electrical connections and vacuum hoses. Disconnect fuel lines. See «FUEL LINE DISCONNECT FITTINGS»(ref-97921-S32383386532001051500000) . Remove throttle body, generator and starter. Remove power steering pump with hoses attached, and set aside (if equipped). Raise and support vehicle. Disconnect exhaust pipe at manifold. Remove starter.
4. Support transmission and attach lifting hoist to engine. Remove engine front mount bolts. Raise engine until engine front mounts clear crossmember brackets. Disconnect clutch release assembly. Remove transmission-to-clutch housing bolts. Move engine forward until transmission shaft clears clutch disc. Remove engine from vehicle.

Removal (Wrangler)

1. Pad windshield with cloth. Raise hood and rest it against windshield frame. Drain cooling system. Remove battery. Disconnect wiring from generator, ignition coil, distributor, oil pressure sender and fuel injection wire harness.
2. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97921-S32383386532001051500000) . Remove fuel line and bracket. See «FUEL LINE DISCONNECT FITTINGS»(ref-97921-S32383386532001051500000) . Remove engine ground strap. Remove air cleaner. Disconnect vacuum purge hose from vapor canister "T". Unplug idle speed actuator connector. Disconnect throttle cable and remove cable from bracket.
3. Disconnect throttle rod at bellcrank. Unplug HO2S sensor connector. Disconnect coolant hoses at radiator, intake manifold and thermostat housing. Remove fan shroud and radiator. Remove fan and spacer. Install a 5/16 x 1/2" bolt through fan pulley into water pump flange to maintain pulley and water pump alignment.
4. Remove check valve from power brake booster. Disconnect power steering hoses at steering gear (if equipped). Drain power steering pump reservoir. Cap power steering hoses and fittings.
5. Tag and disconnect any remaining hoses or electrical connectors. Raise and support vehicle. Disconnect exhaust pipe from exhaust manifold. Remove starter and oil filter. Remove flywheel housing access cover. Remove engine mount through-bolts. Remove upper bellhousing bolts. Loosen lower bellhousing bolts.
6. Lower vehicle. Attach lifting device to engine. Raise engine from front supports. Place support under bellhousing. Remove remaining bellhousing bolts. Lift engine from engine compartment.

Installation

Remove engine mount cushions from brackets to aid alignment of engine and transmission. To complete installation, reverse removal procedure. Adjust throttle cable cable. See THROTTLE CABLE ADJUSTMENT under ADJUSTMENTS. Bleed power steering system. See POWER STEERING BLEEDING . Tighten bolts to specification. See TORQUE SPECIFICATIONS . Refill and check fluid levels.

Removal

1. Disconnect negative battery cable. Remove air inlet hose at throttle body and air cleaner. Remove power steering pump with hoses attached, and wire aside.
2. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97921-S32383386532001051500000). Remove power steering pump brackets at water pump and intake manifold. Disconnect fuel supply and return lines at fuel rail. See «FUEL LINE DISCONNECT FITTINGS»(ref-97921-S32383386532001051500000).
3. Disconnect accelerator cable. Unplug cruise control connector at throttle body using only finger pressure. Remove crankcase ventilation and manifold pressure sensor hoses. Tag and disconnect all wiring and hoses.
4. Remove bolts No. 2 through 5 securing intake manifold to cylinder head. (Scheme 23) Slightly loosen bolt No. 1 and nuts No. 6 and 7. Remove intake manifold. Drain coolant from manifold.

Scheme 23

Ensure all gasket surfaces are clean. Install intake manifold. Finger tighten all bolts. Tighten intake manifold bolts to specification in correct sequence. (Scheme 23) Also see TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Fill and bleed cooling system.

Disconnect negative battery cable. Remove intake manifold. See INTAKE MANIFOLD . Raise and support vehicle. Disconnect exhaust pipe from exhaust manifold. Lower vehicle. Remove retaining nuts and bolts. Remove exhaust manifold.

1. Clean all gasket surfaces. Install intake and exhaust manifolds together, using NEW gasket. Ensure exhaust manifold is centrally located over end studs and spacer. Tighten bolt No. 1 to specification. See «TORQUE SPECIFICATIONS»(ref-97921-S09687572562001051500000). Tighten bolts No. 2 through 5 to specification in sequence. (Scheme 23)
2. Install NEW spacers over cylinder head studs. Tighten nuts No. 6 and 7 to specification. To complete installation, reverse removal procedure. Start engine and check for leaks.

1. Disconnect negative battery cable. Disconnect Crankcase Ventilation (CCV) vacuum hose. Disconnect air cleaner assembly. Drain cooling system. Remove accessory drive belt. Remove A/C compressor (if equipped), and wire aside. DO NOT discharge A/C system. Remove air cleaner.
2. Remove A/C compressor mounting bracket-to-cylinder head bolts. Loosen A/C compressor mounting bracket-to-cylinder block bolts. If equipped, disconnect power steering pump bracket, and set aside. DO NOT disconnect power steering hoses. Remove fuel lines and vacuum advance hose. See «FUEL PRESSURE RELEASE»(ref-97921-S32383386532001051500000) . Disconnect upper radiator hose and heater hoses. Remove valve cover.
3. Remove rocker arms, bridges, pivots and push rods. Tag all parts for installation reference. See «ROCKER ARMS»(ref-97921-S25181137302001051500000) . Remove manifolds. See «INTAKE MANIFOLD»(ref-97921-S39990436642001051500000) and «EXHAUST MANIFOLD»(ref-97921-S36937294172001051500000) .
4. Tag and disconnect spark plug wires. Remove spark plugs. Remove cylinder head bolts. Remove cylinder head. Stuff clean, lint-free shop towels into cylinder bores.

1. Clean carbon from combustion chambers and tops of pistons. Ensure all gasket surfaces, head bolts and head bolt holes are clean. Install NEW cylinder head gasket with numbers or word TOP upward. DO NOT apply sealant to cylinder head gasket. Fabricate 2 engine cylinder head alignment dowels from used head bolts. Use longest head bolts. Cut head off bolt and cut a slot in top of dowel. Ensure all holes align properly.
2. Install cylinder head. Apply sealing compound to threads of cylinder head bolt No. 7 before installation. Install cylinder head bolts. Tighten all bolts in 3 stages and in sequence to specification. (Scheme 24) See «TORQUE SPECIFICATIONS»(ref-97921-S09687572562001051500000). NOTE: During final tightening sequence, bolt No. 7 will require only 100 ft. lbs. (136 N.m) torque.
3. To complete installation, reverse removal procedure. Install all valve train components into their original locations. Refill cooling system. Remove coolant temperature sensor to bleed air from system while filling.

Scheme 24

1. Disconnect negative battery cable. Remove drive belt. Remove vibration damper. Remove radiator shroud. Remove key. Remove seal from front cover. Apply sealant to outer diameter of NEW seal. Coat crankshaft lightly with oil.
2. Drive seal into front cover, using Front Cover Aligner/Seal Installer (6139). Lightly coat seal contact area of vibration damper with oil. Lubricate vibration damper bolt with oil before installation. Apply silicone adhesive to keyway before inserting key. Reverse removal procedure to complete installation. See «TORQUE SPECIFICATIONS»(ref-97921-S09687572562001051500000) .

1. Disconnect negative battery cable. Remove drive belt, fan and hub assembly. Remove fan shroud. Remove accessory brackets attached to timing case cover. Remove A/C compressor (if equipped) with hoses attached, and wire aside. DO NOT discharge A/C system. Remove generator bracket assembly from cylinder head.
2. Remove vibration damper retaining bolt and washer. Remove vibration damper and key. Remove front cover retaining bolts and front cover. Cut oil pan gasket flush with face of cylinder block. Remove cut off pieces.
3. Rotate crankshaft until timing marks on crankshaft and camshaft sprockets align. (Scheme 25) Remove oil slinger and camshaft sprocket retaining bolt. Remove sprockets and chain as an assembly. Remove front cover oil seal.

Scheme 25

Scheme 26

1. Apply silicone adhesive to keyway before inserting key. Turn tensioner lever down to unlock position. Pull tensioner block toward lever to compress spring. Turn lever up to lock position. (Scheme 26) Install timing chain and sprockets as an assembly. Ensure timing marks align. Install camshaft sprocket retaining bolt and washer. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-97921-S09687572562001051500000). NOTE: Ensure chain tensioner is in unlock (down) position before installing front cover.
2. Verify proper installation by rotating crankshaft until timing mark on camshaft is at approximately one o'clock position. Timing sprockets are installed correctly if there are 20 timing chain pins between timing marks on both sprockets.
3. Clean all gasket surfaces. Install oil slinger. Apply sealing compound onto both sides of front cover gasket. Install gasket onto cylinder block. Replace front section of oil pan seal with similar piece cut from NEW seal.
4. Coat outer surface of NEW seal with RTV sealant, and place into position. Apply sealant where oil pan and cylinder block meet. Place front cover onto cylinder block. Place Front Cover Aligner/Seal Installer (6139) into front engine cover seal area.
5. Install cover retaining bolts, and tighten to specification. To complete installation, reverse removal procedure. Lubricate vibration damper retaining bolt before installation, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-97921-S09687572562001051500000).

Remove valve cover. Alternately loosen rocker arm cap screws one turn at a time to prevent damaging bridges. Remove bridges, pivots, rocker arms and push rods. Tag all parts for reassembly reference.

1. Lubricate push rod ends with MOPAR® Engine Oil Supplement (4318002) or equivalent. Install push rods into their original locations. Ensure bottom end of each push rod is centered in valve lifter.
2. Lubricate pivot contact area of each rocker arm with engine oil supplement. Install rocker arms, pivots and bridges into their original locations. Loosely install cap screws, then tighten alternately one turn at a time to specification. Reverse removal procedure to complete installation.
3. Pour remaining engine oil supplement over entire valve train. Supplement must remain in engine oil for at least 1000 miles, but need not be drained until next scheduled oil change.

1. Disconnect negative battery cable. Drain cooling system. Discharge A/C system (if equipped), using approved refrigerant recovery/recycling equipment. Remove A/C condenser (if equipped) and radiator. Mark distributor and engine block for installation reference. Remove distributor and ignition wiring. Remove rocker arms, bridges, pivots and push rods. See «ROCKER ARMS»(ref-97921-S25181137302001051500000) .
2. Remove valve lifters using Hydraulic Valve Lifter Remover/Installer (C-4129-A). Tag each valve lifter for installation reference. Remove timing chain and sprockets. See «TIMING CHAIN & SPROCKETS»(ref-97921-S34557735022001051500000) . Remove camshaft.

1. Lubricate camshaft and dip valve lifters into MOPAR® Engine Oil Supplement (4318002) or equivalent. Install camshaft. Reverse removal procedure to complete installation.
2. Pour remaining oil supplement over entire valve train. Supplement must remain in engine oil for at least 1000 miles, but need not be drained until next scheduled oil change. Refill cooling system. Adjust ignition timing. Check for leaks.

Remove transmission, clutch housing and flywheel or flexplate. Pry oil seal from housing. Avoid damage to surrounding area.

Coat outer lip of replacement seal with engine oil. Using Installer (6271), install seal flush with cylinder block. Use NEW bolts when installing flywheel or flexplate. Ensure felt lip is inside flywheel mounting surface to avoid tearing seal. To complete installation, reverse removal procedure. Tighten flywheel or flexplate bolts to specification, then turn an additional 60 degrees. See TORQUE SPECIFICATIONS .

Disconnect negative battery cable. Drain cooling system. Remove fan shroud and drive belts. Remove fan assembly. Disconnect heater hoses and lower radiator hose at water pump. Remove water pump retaining bolts. Remove water pump.

Install water pump. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Ensure pump turns freely. Ensure belt is installed correctly to prevent water pump turning in wrong direction. See drive belt routing in appropriate article in ENGINE COOLING. To complete installation, reverse removal procedure. Fill cooling system with coolant, and purge air from system. Remove coolant temperature sensor to bleed air from system while filling. See COOLING SYSTEM BLEEDING under REMOVAL & INSTALLATION.

1. Disconnect negative battery cable. Raise and support vehicle at side sills. Drain engine oil. Disconnect exhaust pipe at exhaust manifold. Disconnect exhaust hanger at catalytic converter. Lower exhaust pipe. Remove starter. Remove flywheel access cover.
2. Position jackstand directly under vibration damper. Place wooden block between vibration damper and jackstand. Remove through bolts from engine mounts. Raise engine enough to remove oil pan. Remove oil pan retaining bolts. Remove oil pan by sliding it to rear.

1. Ensure all gasket surfaces are clean. Fabricate 4 alignment dowels from 1/4"-20 x 1 1/2" bolts. Cut heads off bolts and cut slot into end of bolts to allow removal with screwdriver. Install 2 dowels into timing cover and 2 dowels into engine block. Slide gasket over dowels into position against block and timing cover.
2. Install oil pan. Install sufficient bolts to hold oil pan in place. Remove alignment dowels. Install remaining oil pan bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-97921-S09687572562001051500000) . To complete installation, reverse removal procedure. Fill crankcase. Start engine. Check for leaks.

Removal & Disassembly

Remove oil pump retaining bolts. DO NOT move oil pick-up pipe in pump body. If oil pick-up pipe is moved, pick-up pipe must be replaced to ensure an airtight seal. Remove pump cover. Disassemble pump.

Reassembly & Installation

1. Apply sealant to pick-up pipe and pump cover area prior to installation. To install pick-up tube, use Pipe Installer (7624). Ensure pick-up pipe support bracket is aligned with pump cover bolt. If relief valve is replaced, ensure replacement valve is same diameter as that removed.
2. Fill pump cavity with petroleum jelly. Install cover. Tighten cover bolts to specification. Check pump gears for freedom of rotation. Install NEW gasket and oil pump. Tighten retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97921-S09687572562001051500000) .