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Dodge Dakota 1991 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Dakota Year: 1991 Generation: First Generation (AN Body Style) Codes Body Style: Compact Pickup Truck Chassis Code: AN 👋 Introduction Market Position Segment: Compact Pickup Truck Competitive Analysis Key Competitors: Ford Ranger, Chevrolet S-10, Nissan Hardbody, Toyota Pickup Key Features Distinguishing Features: First compact pickup from a 'big three' American manufacturer, offering V8 engine option, available 4WD, and a range of cab and bed configurations. Manual Value Utility: Essential for owners and technicians seeking accurate, factory-authorized repair information for the 1991 Dodge Dakota. 📋 Manual Details Coverage Areas Regions Covered: North America (USA, Canada) Page Count Estimated Pages: Hundreds (specific number not provided in product info, but indicates substantial content) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: 2.5L Mag-Flex (4-cylinder), 3.9L LA (V6), 5.2L LA (V8) Transmission: Manual (Getrag 360), Automatic (A500, A518) Brakes: Front disc, rear drum; ABS (optional) Suspension: Front independent, rear solid axle with leaf springs Electrical: Charging system, starting system, ignition, lighting, instruments, accessories, wiring diagrams Steering: Power steering system Cooling System: Radiator, fan, water pump, thermostat, coolant specifications Fuel System: Fuel pump, injectors, fuel pressure, evaporative emissions (EVAP) Exhaust System: Catalytic converter, mufflers, pipes HVAC: Heating, Ventilation, Air Conditioning system components and service Body: Body construction, interior trim, exterior panels, doors, glass, bumpers Chassis: Frame, axles, driveshaft, universal joints Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, lubrication Troubleshooting: Diagnostic charts, symptom analysis, common fault identification Repair: Component removal, installation, adjustment, and rebuild procedures Diagnostics: Engine diagnostics, ABS diagnostics, electrical system troubleshooting Specifications: Torque values, clearances, fluid capacities, electrical specifications Wiring Diagrams: Comprehensive electrical system schematics Engine Mechanical: Engine assembly, disassembly, cylinder head service, piston/ring replacement, crankshaft/bearing service. Transmission Overhaul: Detailed steps for rebuilding both manual and automatic transmissions. Brake System Service: Front brake pad replacement, caliper service, rear drum brake adjustment and relining, ABS hydraulic unit service (if equipped). Suspension And Steering Service: Ball joint replacement, tie rod end service, shock absorber replacement, steering gear inspection and adjustment. Body And Interior Repair: Door panel removal, seat removal, glass replacement, bumper alignment and repair. Diagnostics Troubleshooting Charts: Systematic approach to identifying and resolving common vehicle problems. Technical Depth Depth: Complete factory-level service and repair procedures, including engine overhauls, transmission rebuilds, and detailed electrical diagnostics. Diagnostic Tools: Information relevant for basic OBD-I diagnostic code retrieval (if applicable for specific sensors) and general electronic system checks. Special Tools: Lists and descriptions of specialized tools required for specific repair procedures. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: High-resolution, printable pages Binding Type Type: Digital Download (Printable) Paper Type Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine 1: 2.5L Mag-Flex (AMC I4) Engine 2: 3.9L LA (Chrysler Mopar V6) Engine 3: 5.2L LA (Chrysler Mopar V8) Performance 2.5L Hp: Approx. 100-116 hp (depending on specific tuning) 3.9L Hp: Approx. 125-130 hp 5.2L Hp: Approx. 170-180 hp 3.9L Torque: Approx. 180-195 lb-ft 5.2L Torque: Approx. 240-250 lb-ft Fuel System Injection Type: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Technical Details Engine Code 2.5L: 2.5L Mag-Flex Engine Code 3.9L: 3.9L LA Engine Code 5.2L: 5.2L LA 🔧 Transmission Standard Manual Transmission: Getrag 360 5-speed manual Optional Automatic Transmission: Chrysler A500 4-speed automatic (with overdrive); A518 for V8 models Features 4Wd Transfer Case: New Process NP231 (manual shift) or NP243 (electronic shift for later models, though less common in '91) Fluid Specifications Manual Fluid: GL-5 Gear Oil (e.g., SAE 75W-90) Automatic Fluid: ATF+3 (or equivalent) 📐 Dimensions Exterior Wheelbase Regular Cab: 112.1 inches Wheelbase Extended Cab: 124.1 inches Bed Lengths: 6.5 feet (standard), 8 feet (long bed) Weights Curb Weight Range: Approx. 3,100 - 4,000 lbs (depending on configuration) Towing Capacity Range: Varies significantly by engine and drivetrain, up to approx. 6,000-7,000 lbs for V8 models. 🛡️ Safety Features Ratings NHTSA Ratings: Limited data available for this era, generally basic for pickups. Active Features ABS: Optional Anti-lock Braking System (ABS) on rear wheels only for 1991. Passive Features Airbags: Driver-side airbag was optional, not standard. Seat Belts: Three-point front seat belts 💡 Technology Features Infotainment Audio System: AM/FM radio with cassette player, optional CD player (rare for this year). Driver Assistance Features: Basic driver aids, primarily focused on mechanical systems rather than electronic assistance. Connectivity Features: No modern connectivity features (Bluetooth, USB, etc.). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles or 6 months (refer to manual for specific engine/oil type) Tune Up Interval: Spark plugs and filters typically every 30,000-60,000 miles Fluid Specifications Engine Oil Type: API SG or SH, SAE 10W-30 or 5W-30 (refer to manual for specific viscosity based on temperature) Coolant Type: Ethylene Glycol based coolant, typically a 50/50 mix with distilled water Brake Fluid Type: DOT 3...
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Dodge Dakota 1991 Factory Service Repair ManualDodge Dakota 1991 Factory Service Repair ManualDodge Dakota 1991 Factory Service Repair ManualDodge Dakota 1991 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Dakota
Year:
1991
Generation:
First Generation (AN Body Style)
Codes
Body Style:
Compact Pickup Truck
Chassis Code:
AN
👋 Introduction
Market Position
Segment:
Compact Pickup Truck
Competitive Analysis
Key Competitors:
Ford Ranger, Chevrolet S-10, Nissan Hardbody, Toyota Pickup
Key Features
Distinguishing Features:
First compact pickup from a 'big three' American manufacturer, offering V8 engine option, available 4WD, and a range of cab and bed configurations.
Manual Value
Utility:
Essential for owners and technicians seeking accurate, factory-authorized repair information for the 1991 Dodge Dakota.
📋 Manual Details
Coverage Areas
Regions Covered:
North America (USA, Canada)
Page Count
Estimated Pages:
Hundreds (specific number not provided in product info, but indicates substantial content)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
2.5L Mag-Flex (4-cylinder), 3.9L LA (V6), 5.2L LA (V8)
Transmission:
Manual (Getrag 360), Automatic (A500, A518)
Brakes:
Front disc, rear drum; ABS (optional)
Suspension:
Front independent, rear solid axle with leaf springs
Electrical:
Charging system, starting system, ignition, lighting, instruments, accessories, wiring diagrams
Steering:
Power steering system
Cooling System:
Radiator, fan, water pump, thermostat, coolant specifications
Fuel System:
Fuel pump, injectors, fuel pressure, evaporative emissions (EVAP)
Exhaust System:
Catalytic converter, mufflers, pipes
HVAC:
Heating, Ventilation, Air Conditioning system components and service
Body:
Body construction, interior trim, exterior panels, doors, glass, bumpers
Chassis:
Frame, axles, driveshaft, universal joints
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, lubrication
Troubleshooting:
Diagnostic charts, symptom analysis, common fault identification
Repair:
Component removal, installation, adjustment, and rebuild procedures
Diagnostics:
Engine diagnostics, ABS diagnostics, electrical system troubleshooting
Specifications:
Torque values, clearances, fluid capacities, electrical specifications
Wiring Diagrams:
Comprehensive electrical system schematics
Engine Mechanical:
Engine assembly, disassembly, cylinder head service, piston/ring replacement, crankshaft/bearing service.
Transmission Overhaul:
Detailed steps for rebuilding both manual and automatic transmissions.
Brake System Service:
Front brake pad replacement, caliper service, rear drum brake adjustment and relining, ABS hydraulic unit service (if equipped).
Suspension And Steering Service:
Ball joint replacement, tie rod end service, shock absorber replacement, steering gear inspection and adjustment.
Body And Interior Repair:
Door panel removal, seat removal, glass replacement, bumper alignment and repair.
Diagnostics Troubleshooting Charts:
Systematic approach to identifying and resolving common vehicle problems.
Technical Depth
Depth:
Complete factory-level service and repair procedures, including engine overhauls, transmission rebuilds, and detailed electrical diagnostics.
Diagnostic Tools:
Information relevant for basic OBD-I diagnostic code retrieval (if applicable for specific sensors) and general electronic system checks.
Special Tools:
Lists and descriptions of specialized tools required for specific repair procedures.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Quality:
High-resolution, printable pages
Binding Type
Type:
Digital Download (Printable)
Paper Type
Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.5L Mag-Flex (AMC I4)
Engine 2:
3.9L LA (Chrysler Mopar V6)
Engine 3:
5.2L LA (Chrysler Mopar V8)
Performance
2.5L Hp:
Approx. 100-116 hp (depending on specific tuning)
3.9L Hp:
Approx. 125-130 hp
5.2L Hp:
Approx. 170-180 hp
3.9L Torque:
Approx. 180-195 lb-ft
5.2L Torque:
Approx. 240-250 lb-ft
Fuel System
Injection Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Technical Details
Engine Code 2.5L:
2.5L Mag-Flex
Engine Code 3.9L:
3.9L LA
Engine Code 5.2L:
5.2L LA
🔧 Transmission
Standard
Manual Transmission:
Getrag 360 5-speed manual
Optional
Automatic Transmission:
Chrysler A500 4-speed automatic (with overdrive); A518 for V8 models
Features
4Wd Transfer Case:
New Process NP231 (manual shift) or NP243 (electronic shift for later models, though less common in '91)
Fluid Specifications
Manual Fluid:
GL-5 Gear Oil (e.g., SAE 75W-90)
Automatic Fluid:
ATF+3 (or equivalent)
📐 Dimensions
Exterior
Wheelbase Regular Cab:
112.1 inches
Wheelbase Extended Cab:
124.1 inches
Bed Lengths:
6.5 feet (standard), 8 feet (long bed)
Weights
Curb Weight Range:
Approx. 3,100 - 4,000 lbs (depending on configuration)
Towing Capacity Range:
Varies significantly by engine and drivetrain, up to approx. 6,000-7,000 lbs for V8 models.
🛡️ Safety Features
Ratings
NHTSA Ratings:
Limited data available for this era, generally basic for pickups.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) on rear wheels only for 1991.
Passive Features
Airbags:
Driver-side airbag was optional, not standard.
Seat Belts:
Three-point front seat belts
💡 Technology Features
Infotainment
Audio System:
AM/FM radio with cassette player, optional CD player (rare for this year).
Driver Assistance
Features:
Basic driver aids, primarily focused on mechanical systems rather than electronic assistance.
Connectivity
Features:
No modern connectivity features (Bluetooth, USB, etc.).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 6 months (refer to manual for specific engine/oil type)
Tune Up Interval:
Spark plugs and filters typically every 30,000-60,000 miles
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 10W-30 or 5W-30 (refer to manual for specific viscosity based on temperature)
Coolant Type:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water
Brake Fluid Type:
DOT 3
Power Steering Fluid:
ATF+3 or Mopar Power Steering Fluid
Transfer Case Fluid:
ATF+3 or equivalent for NP231/NP243
Known Issues
Common Problems:
Rust (especially in wheel wells, rocker panels), distributor gear wear (on older Mopar V6/V8), electrical connector corrosion, rear main seal leaks, carburetor issues (on very early models, though EFI is standard by '91).
Filter Part Numbers
Oil Filter Example:
Wix 51515, Fram PH8A (verify for specific engine)
📚 Vehicle History
Brand Heritage
Dodge Trucks:
Dodge had a long history of truck production, but the Dakota was their first foray into the compact/mid-size pickup segment.
Model Evolution
Introduction Year:
1987
First Generation Years:
1987-1996
Production
Manufacturing Plant:
Warren Truck Assembly Plant, Warren, Michigan
🏆 Awards & Recognition
Recognitions
Industry Awards:
The first-generation Dakota was generally well-received for its size, capability, and available V8 power, filling a market gap.
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