Dakota, 2001-2005

Engine

Print

Removal & Installation



2.5L, 3.9L & 5.9L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:
    WARNING
    Do not lift the engine by the intake manifold. Damage to the manifold may result.



    Negative battery cable
     
    Hood
     
    Upper crossmember and top core support
     
    Radiator hoses
     
    Cooling fan and shroud
     
    Radiator
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Heater hoses
     
    Intake manifold vacuum lines
     
    Accessory drive belt
     
    Power steering pump
     
    A/C compressor, if equipped
     
    Engine control sensor harness connectors
     
    Engine block heater, if equipped
     
    Fuel line
     
    Exhaust front pipe
     
    Starter motor
     
    Torque converter, if equipped
     
    Transmission oil cooler lines, if equipped
     
    Engine mounts
     
    Transmission flange bolts. Support the transmission.
     
    Engine
     

  10.  

To install:

  1. Install or connect the following:

    Engine. Tighten the engine mount bolts to 70 ft. lbs. (95 Nm).
     
    Transmission flange bolts. Tighten the bolts to 40-45 ft. lbs. (54-61 Nm).
     
    Transmission oil cooler lines, if equipped
     
    Torque converter, if equipped. Tighten the bolts to 23 ft. lbs. (31 Nm).
     
    Starter motor
     
    Exhaust front pipe
     
    Fuel line
     
    Engine block heater, if equipped
     
    Engine control sensor harness connectors
     
    A/C compressor, if equipped
     
    Power steering pump
     
    Accessory drive belt
     
    Intake manifold vacuum lines
     
    Heater hoses
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator cable
     
    Radiator
     
    Cooling fan and shroud
     
    Radiator hoses
     
    Upper crossmember and top core support
     
    Hood
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

3.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Discharge the A/C system.
  4.  
  5. Drain the cooling system.
  6.  
  7. Release the fuel rail pressure.
  8.  
  9. Remove the air cleaner assembly.
  10.  
  11. Disconnect the battery.
  12.  
  13. Remove the upper fan shroud.
  14.  
  15. Remove the accessory drive belt.
  16.  
  17. Remove the viscous fan.
  18.  
  19. Remove the A/C compressor and position out of the way.
  20.  
  21. Remove the generator and secure away from engine.
    NOTE
    Do not remove the phenolic pulley from the P/S pump. It is not required for P/S pump removal.

  22.  
  23. Remove the power steering pump with lines attached and secure away from engine.
  24.  
  25. Disconnect the heater hoses from the engine.
  26.  
  27. Disconnect the heater hoses from heater core and remove the hose assembly.
  28.  
  29. Remove the upper radiator hose from engine.
  30.  
  31. Remove the lower radiator hose from engine.
  32.  
  33. Disconnect the transmission oil cooler lines at the radiator.
  34.  
  35. Remove the radiator core support bracket.
  36.  
  37. Remove the radiator assembly, A/C Condenser and transmission oil cooler.
  38.  
  39. Disconnect throttle and speed control cables.
  40.  
  41. Disconnect the engine to body ground straps at the left side of cowl.
  42.  
  43. Disconnect the engine wiring harness at the following points:

    Intake air temperature (IAT) sensor
     
    Fuel Injectors
     
    Throttle Position (TPS) Switch
     
    Idle Air Control (IAC) Motor
     
    Engine Oil Pressure Switch
     
    Engine Coolant Temperature (ECT) Sensor
     
    Manifold Absolute Pressure MAP) Sensor
     
    Camshaft Position (CMP) Sensor
     
    Coil Over Plugs
     
    Crankshaft Position Sensor
     

  44.  
  45. Remove the coil over plugs.
  46.  
  47. Remove fuel rail and secure away from engine.
    NOTE
    It is not necessary to release the quick connect fitting from the fuel supply line for engine removal.

  48.  
  49. Remove the PCV hose.
  50.  
  51. Remove the breather hoses.
  52.  
  53. Remove the vacuum hose for the power brake booster.
  54.  
  55. Disconnect the knock sensors.
  56.  
  57. Remove the engine oil dipstick tube.
  58.  
  59. Remove the intake manifold.
  60.  
  61. Install the engine lifting fixture, special tool 8247, using original fasteners from the removed intake manifold, and fuel rail.
  62.  
  63. Raise the vehicle on hoist.
  64.  
  65. Remove the exhaust crossover pipe from exhaust manifolds.
  66.  
  67. On 4wd vehicles, disconnect the axle vent tube from the left side engine mount.
  68.  
  69. Remove the through bolt retaining nut and bolt from both the left and right side engine mounts.
  70.  
  71. On 4wd vehicles, remove the locknut from the left and right side engine mount brackets.
  72.  
  73. Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine.
  74.  
  75. Disconnect the crankshaft position sensor.
    NOTE
    The following step applies to 4wd vehicles equipped with automatic transmission only.

  76.  
  77. On 4wd vehicles, remove the axle isolator bracket from the engine, transmission and the axle.
  78.  
  79. Remove the structural cover.
  80.  
  81. Remove the starter.
  82.  
  83. Remove the torque converter bolts (automatic transmission only).
  84.  
  85. Remove transmission to engine mounting bolts.
  86.  
  87. Disconnect the engine block heater power cable from the block heater, if equipped.
  88.  
  89. Lower the vehicle.
  90.  
  91. Remove throttle body resonator assembly and air inlet hose.
  92.  
  93. Disconnect the throttle and speed control cables.
  94.  
  95. Disconnect the tube from both the left and right side crankcase breathers. Remove the breathers.
  96.  
  97. Remove the generator.
  98.  
  99. Disconnect the two heater hoses from the timing chain cover and heater core.
  100.  
  101. Unclip and remove the heater hoses and tubes from the intake manifold.
  102.  
  103. Disconnect the engine harness at the following points:

    Intake air temperature (IAT) sensor
     
    Fuel Injectors
     
    Throttle Position (TPS) Switch
     
    Idle Air Control (IAC) Motor
     
    Engine Oil Pressure Switch
     
    Engine Coolant Temperature (ECT) Sensor
     
    Manifold absolute pressure (MAP) Sensor
     
    Camshaft Position (CMP) Sensor
     
    Coil Over Plugs
     

  104.  
  105. Disconnect the vacuum lines at the throttle body and intake manifold.
  106.  
  107. Remove the power steering pump and position out of the way.
  108.  
  109. Disconnect the body ground strap at the right side cowl.
  110.  
  111. Disconnect the body ground strap at the left side cowl.
    NOTE
    It will be necessary to support the transmission in order to remove the engine.

  112.  
  113. Position a suitable jack under the transmission.
  114.  
  115. Remove the engine from the vehicle.
  116.  

To install:

Click image to see an enlarged view

Fig. Engine mount through-bolt removal-3.7L engine w/2WD



Click image to see an enlarged view

Fig. Engine mount through-bolt removal-3.7L engine w/4WD



Click image to see an enlarged view

Fig. Axle isolator bracket removal-3.7L engine w/4wd

  1. Position the engine in the vehicle. Position both the left and right side engine mount brackets and install the through bolts and nuts. On 2WD vehicles, tighten nuts to 95 Nm (70 ft. lbs.); on 4wd vehicles, to 102 Nm (75 ft. lbs.).
  2.  
  3. On 4wd vehicles, install the locknuts onto the engine mount brackets. Tighten the locknuts to 41 Nm (30 ft. lbs.).
  4.  
  5. Remove the jack from under the transmission.
  6.  
  7. Remove Engine Lifting Fixture Tool 8347.
  8.  
  9. Remove Special Tools 8400 Lifting Studs.
  10.  
  11. Position the generator wiring behind the oil dipstick tube, then install the oil dipstick tube upper mounting bolt.
  12.  
  13. Connect both left and right side body ground straps.
  14.  
  15. Install the power steering pump.
  16.  
  17. Connect the fuel supply line quick connect fitting.
  18.  
  19. Connect the vacuum lines at the throttle body and intake manifold.
  20.  
  21. Connect the engine harness at the following points:

    Intake Air Temperature (IAT) Sensor
     
    Idle Air Control (IAC) Motor
     
    Fuel Injectors
     
    Throttle Position (TPS) Switch
     
    Engine Oil Pressure Switch
     
    Engine Coolant Temperature (ECT) Sensor
     
    Manifold Absolute Pressure (MAP) Sensor
     
    Camshaft Position (CMP) Sensor
     
    Coil Over Plugs
     

  22.  
  23. Position and install the heater hoses and tubes onto intake manifold.
  24.  
  25. Install the heater hoses onto the heater core and the engine front cover.
  26.  
  27. Install the generator.
  28.  
  29. Install the A/C condenser, radiator and transmission oil cooler.
  30.  
  31. Connect the radiator upper and lower hoses.
  32.  
  33. Connect the transmission oil cooler lines to the radiator.
  34.  
  35. Install the accessory drive belt, fan assembly and shroud.
  36.  
  37. Install A/C compressor.
  38.  
  39. Install both breathers. Connect the tube to both crankcase breathers.
  40.  
  41. Connect the throttle and speed control cables.
  42.  
  43. Install the throttle body resonator assembly and air inlet hose. Tighten the clamps to 4 Nm (35 inch lbs.).
  44.  
  45. Raise the vehicle.
  46.  
  47. Install the transmission to engine mounting bolts. Tighten the bolts to 41 Nm (30 ft. lbs.).
  48.  
  49. Install the torque converter bolts (automatic transmission only).
  50.  
  51. Connect the crankshaft position sensor.
  52.  
  53. On 4wd vehicles, position and install the axle isolator bracket onto the axle, transmission and engine block.
  54.  
  55. Install the starter.
    WARNING
    The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.

  56.  
  57. Install the structural cover.
  58.  
  59. Install the exhaust crossover pipe.
  60.  
  61. Install the engine block heater power cable, if equipped.
  62.  
  63. On 4wd vehicles, connect the axle vent tube to the left side engine mount.
  64.  
  65. Lower the vehicle.
  66.  
  67. Check and fill engine oil.
  68.  
  69. Recharge the A/C system.
  70.  
  71. Refill the engine cooling system.
  72.  
  73. Install the battery tray and battery.
  74.  
  75. Connect the battery positive and negative cables.
  76.  
  77. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Tighten the structural cover bolts in this order-3.7L Engine

  78.  

4.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the battery negative and positive cables.
  4.  
  5. Remove the battery and the battery tray.
  6.  
  7. Raise the vehicle on hoist.
  8.  
  9. Remove exhaust crossover pipe from the exhaust manifolds.
  10.  
  11. On 4wd vehicles, disconnect the axle vent tube from left side engine mount.
  12.  
  13. Remove the through bolt retaining nut and bolt from both the left and right side engine mounts.
  14.  
  15. On 4wd vehicles, remove the locknut from left and right side engine mount brackets.
  16.  
  17. Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine.
  18.  
  19. Disconnect the crankshaft position sensor.
    NOTE
    The following step applies to 4X4 vehicles equipped with automatic transmission only.

  20.  
  21. On 4wd vehicles, remove the axle isolator bracket from the engine, transmission and the axle.
  22.  
  23. Remove the structural cover.
  24.  
  25. Remove the starter.
  26.  
  27. Drain the cooling system.
  28.  
  29. Remove the torque converter bolts (automatic transmission only).
  30.  
  31. Remove the transmission to engine mounting bolts.
  32.  
  33. Disconnect the engine block heater power cable from the block heater, if equipped.
  34.  
  35. Lower the vehicle.
  36.  
  37. Remove the throttle body resonator assembly and air inlet hose.
  38.  
  39. Disconnect the throttle and speed control cables.
  40.  
  41. Disconnect the tube from both the left and right side crankcase breathers. Remove breathers.
  42.  
  43. Discharge the A/C system.
  44.  
  45. Remove the A/C compressor.
  46.  
  47. Remove the shroud, fan assembly and accessory drive belt.
  48.  
  49. Disconnect the transmission oil cooler lines at the radiator.
  50.  
  51. Disconnect the radiator upper and lower hoses.
  52.  
  53. Remove the radiator, A/C condenser and transmission oil cooler.
  54.  
  55. Remove the generator.
  56.  
  57. Disconnect the two heater hoses from the timing chain cover and heater core.
  58.  
  59. Unclip and remove the heater hoses and tubes from the intake manifold.
  60.  
  61. Disconnect the engine harness at the following points :

    Intake air temperature (IAT) sensor
     
    Fuel Injectors
     
    Throttle Position (TPS) Switch
     
    Idle Air Control (IAC) Motor
     
    Engine Oil Pressure Switch
     
    Engine Coolant Temperature (ECT) Sensor
     
    Manifold Absolute Pressure (MAP) Sensor
     
    Camshaft Position (CMP) Sensor
     
    Coil Over Plugs
     

  62.  
  63. Disconnect the vacuum lines at the throttle body and intake manifold.
  64.  
  65. Release the fuel rail pressure then disconnect the fuel supply quick connect fitting at the fuel rail.
  66.  
  67. Remove the power steering pump and position out of the way.
  68.  
  69. Install Special Tools 8400 Lifting Studs, into the cylinder heads.
  70.  
  71. Install Engine Lifting Fixture Special Tool 8347 following these steps:

    Holding the lifting fixture at a slight angle, slide the large bore in the front plate over the hex portion of the lifting stud.
     
    Position the two remaining fixture arms onto the two Special Tools 8400 Lifting Studs, in the cylinder heads.
     
    Pull forward and upward on the lifting fixture so that the lifting stud rest in the slotted area below the large bore.
     
    Secure the lifting fixture to the three studs using three 7 / 16 - 14 N/C locknuts.
     
    Make sure the lifting loop in the lifting fixture is in the last hole (closest to the throttle body) to minimize the angle of engine during removal.
     

  72.  
  73. Disconnect the body ground strap at the right side cowl.
  74.  
  75. Disconnect the body ground strap at the left side cowl.
    NOTE
    It will be necessary to support the transmission in order to remove the engine.

  76.  
  77. Position a suitable jack under the transmission.
  78.  
  79. Remove the engine from the vehicle.
  80.  

To install:

  1. Position the engine in the vehicle. Position both the left and right side engine mount brackets and install the through bolts and nuts. On 2WD vehicles, tighten nuts to 95 Nm (70 ft. lbs.); On 4wd vehicles, tighten to 102 Nm (75 ft. lbs.).
  2.  
  3. On 4wd vehicles, install locknuts onto the engine mount brackets. Tighten the locknuts to 41 Nm (30 ft. lbs.).
  4.  
  5. Remove the jack from under the transmission.
  6.  
  7. Remove Engine Lifting Fixture Special Tool 8347.
  8.  
  9. Remove Special Tools 8400 Lifting Studs.
  10.  
  11. Position the generator wiring behind the oil dipstick tube, then install the oil dipstick tube upper mounting bolt.
  12.  
  13. Connect both left and right side body ground straps.
  14.  
  15. Install the power steering pump.
  16.  
  17. Connect the fuel supply line quick connect fitting.
  18.  
  19. Connect the vacuum lines at the throttle body and intake manifold.
  20.  
  21. Connect the engine harness at the following points:

    Intake Air Temperature (IAT) Sensor
     
    Idle Air Control (IAC) Motor
     
    Fuel Injectors
     
    Throttle Position (TPS) Switch
     
    Engine Oil Pressure Switch
     
    Engine Coolant Temperature (ECT) Sensor
     
    Manifold Absolute Pressure (MAP) Sensor
     
    Camshaft Position (CMP) Sensor
     
    Coil Over Plugs
     

  22.  
  23. Position and install the heater hoses and tubes onto intake manifold.
  24.  
  25. Install the heater hoses onto the heater core and the engine front cover.
  26.  
  27. Install the generator.
  28.  
  29. Install the A/C condenser, radiator and transmission oil cooler.
  30.  
  31. Connect the radiator upper and lower hoses.
  32.  
  33. Connect the transmission oil cooler lines to the radiator.
  34.  
  35. Install the accessory drive belt, fan assembly and shroud.
  36.  
  37. Install the A/C compressor.
  38.  
  39. Install both breathers. Connect the tube to both crankcase breathers.
  40.  
  41. Connect the throttle and speed control cables.
  42.  
  43. Install the throttle body resonator assembly and air inlet hose. Tighten clamps 4 Nm (35 inch lbs.).
  44.  
  45. Raise the vehicle.
  46.  
  47. Install transmission to engine mounting bolts. Tighten the bolts to 41 Nm (30 ft. lbs.).
  48.  
  49. Install the torque converter bolts (automatic transmission only).
  50.  
  51. Connect crankshaft position sensor.
  52.  
  53. On 4wd vehicles, position and install the axle isolator bracket onto the axle, transmission and engine block. Tighten the bolts to specification.
  54.  
  55. Install the starter.
    WARNING
    The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.



    Click image to see an enlarged view

    Fig. Structural cover torque sequence-4.7L engine

  56.  
  57. Install the structural cover.
  58.  
  59. Install the exhaust crossover pipe.
  60.  
  61. Install the engine block heater power cable, if equipped.
  62.  
  63. On 4wd vehicles, connect the axle vent tube to left side engine mount.
  64.  
  65. Lower the vehicle.
  66.  
  67. Check and fill the engine oil.
  68.  
  69. Recharge the A/C system.
  70.  
  71. Refill the engine cooling system.
  72.  
  73. Install the battery tray and battery.
  74.  
  75. Connect the battery positive and negative cables.
  76.  
  77. Start the engine and check for leaks.
  78.  

 
label.common.footer.alt.autozoneLogo