Dodge Dakota 1987-1996 Workshop Service Manual for Repair
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🏷️ Basic Information Identification Make: Dodge Model: Dakota Generation: First Generation Codes: Vehicle Code: ND, Body Style: Pickup Truck 👋 Introduction Market Position Market Position: Compact/Mid-size pickup truck, competing with models like the Ford Ranger, Chevrolet S-10/Sonoma, and Toyota Tacoma. Positioned as a capable and versatile American-made truck. Competitive Analysis Competitive Analysis: The Dodge Dakota offered a compelling blend of compact pickup maneuverability with some of the capability of larger trucks, including available V6 and V8 engines (in later years), which was a significant differentiator against many competitors in its early generation. Key Features Key Features: Rear-wheel drive standard, optional 4-wheel drive, available in regular cab and club cab configurations. Known for its distinctive styling and robust chassis. 📋 Manual Details Coverage Areas Applicable Years: 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 Page Count Page Count: 1431 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication, cooling system, fuel system (carbureted and fuel injected), exhaust system, timing components. Engine Performance: Engine tuning, diagnostics, emissions control, component testing. Transmission Drivetrain: Manual transmissions (A500, A500SE), Automatic transmissions (A500, A518, A618), transfer cases (for 4WD models), driveshafts, axles, differentials, wheel bearings. Brakes: Front disc brakes, rear drum brakes, parking brake system, hydraulic system, ABS (Anti-lock Braking System) for applicable models. Steering Suspension: Power steering system, steering column, steering gear, front suspension (independent torsion bar or coil spring), rear suspension (leaf spring), shock absorbers, control arms, sway bars. Electrical System: Battery, charging system (alternator), starting system, ignition system, lighting system (headlights, taillights, interior), instrument cluster, wiring diagrams, fuses, relays, power distribution. Body Chassis: Body construction, chassis frame, doors, hood, tailgate, bumpers, interior trim, seating, glass, weatherstripping, frame alignment. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant service, blower motor, controls. Fuel System: Fuel tanks, fuel pump, fuel lines, fuel injectors, throttle body, evaporative emission control (EVAP) system. Cruise Control: Diagnosis and repair of the cruise control system, including actuators, control modules, and switches. Instrument Panel: Removal and repair of the instrument cluster, gauges, warning lights, and associated sensors. Procedures Included Maintenance: Scheduled maintenance procedures, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad replacement. Troubleshooting: Diagnostic procedures for common symptoms, fault code interpretation, electrical circuit testing, mechanical component diagnosis. Repair: Step-by-step repair instructions for all major vehicle systems, component removal and installation, engine overhaul, transmission overhaul, brake system repairs, suspension component replacement. Diagnostics: Detailed diagnostic flowcharts, testing procedures for sensors and actuators, use of diagnostic tools. Body Repair: Includes procedures for body panel alignment, glass replacement, door and tailgate adjustments, and interior trim removal/installation. Wheel Tire Service: Information on wheel bearing replacement, tire rotation, and specifications for wheel alignment. Wiring Diagrams: Extensive, system-by-system wiring diagrams for all major electrical components, enabling precise troubleshooting of electrical faults. Emission Controls: Details on catalytic converters, EGR valves, O2 sensors, and the evaporative emission control system, including diagnostic and repair procedures. Technical Depth Technical Depth: Comprehensive from basic maintenance to advanced engine and transmission rebuilds. Includes detailed specifications, torque values, and wiring diagrams. Diagnostic Tools Coverage: Covers basic diagnostic tool usage, multimeter testing, and often references specific Chrysler diagnostic codes (e.g., OBDI) for the era. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, clear text and diagrams, suitable for printing. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Completeness Manual Completeness: Comprehensive, covering all aspects of repair and maintenance for the specified model years, engine options, and trim levels within the first generation. ⚙️ Engine Specifications Primary Engine Engine Options: 2.2L I4 (2249cc), 2.5L I4 (2507cc), 3.0L V6 (Mitsubishi 6G72), 3.9L V6 (50-state), 5.2L V8 (Magnum). Performance Horsepower Range: Approximately 96 hp (2.2L) to 230 hp (5.2L V8). Torque Range: Approximately 119 lb-ft (2.2L) to 300 lb-ft (5.2L V8). Fuel System Fuel System Types: Carbureted (early models, 2.2L/2.5L) and Electronic Fuel Injection (EFI) across various engines and years. Engine Codes Engine Codes: Examples: JX8 (2.5L), K22C (2.2L), AM4 (3.0L V6), AM5 (3.9L V6), JSA (5.2L V8). 🔧 Transmission Standard Standard Transmission: 4-speed Manual Transmission (for 4-cylinder engines), 3-speed Automatic Transmission (for V6 engines). Optional Optional Transmission: 5-speed Manual Transmission (NV3500), 4-speed Automatic Transmission (A500, A518, A618 - especially with V8 engines). Features Transmission Features: Includes detailed procedures for clutch service, transmission fluid changes, seal replacement, and overhaul for both manual and automatic units. 📐 Dimensions Exterior Wheelbase Options: Short bed (approx. 112 inches), Long bed (approx. 124 inches). Weights Curb Weight Range: Approximately 3,000 lbs to 4,000 lbs depending on configuration and engine. 🛡️ Safety Features Ratings Safety Ratings: Information on passive safety features typical for the era;...
Compact/Mid-size pickup truck, competing with models like the Ford Ranger, Chevrolet S-10/Sonoma, and Toyota Tacoma. Positioned as a capable and versatile American-made truck.
Competitive Analysis
Competitive Analysis:
The Dodge Dakota offered a compelling blend of compact pickup maneuverability with some of the capability of larger trucks, including available V6 and V8 engines (in later years), which was a significant differentiator against many competitors in its early generation.
Key Features
Key Features:
Rear-wheel drive standard, optional 4-wheel drive, available in regular cab and club cab configurations. Known for its distinctive styling and robust chassis.
Front disc brakes, rear drum brakes, parking brake system, hydraulic system, ABS (Anti-lock Braking System) for applicable models.
Steering Suspension:
Power steering system, steering column, steering gear, front suspension (independent torsion bar or coil spring), rear suspension (leaf spring), shock absorbers, control arms, sway bars.
Electrical System:
Battery, charging system (alternator), starting system, ignition system, lighting system (headlights, taillights, interior), instrument cluster, wiring diagrams, fuses, relays, power distribution.
Diagnosis and repair of the cruise control system, including actuators, control modules, and switches.
Instrument Panel:
Removal and repair of the instrument cluster, gauges, warning lights, and associated sensors.
Procedures Included
Maintenance:
Scheduled maintenance procedures, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad replacement.
Troubleshooting:
Diagnostic procedures for common symptoms, fault code interpretation, electrical circuit testing, mechanical component diagnosis.
Repair:
Step-by-step repair instructions for all major vehicle systems, component removal and installation, engine overhaul, transmission overhaul, brake system repairs, suspension component replacement.
Diagnostics:
Detailed diagnostic flowcharts, testing procedures for sensors and actuators, use of diagnostic tools.
Body Repair:
Includes procedures for body panel alignment, glass replacement, door and tailgate adjustments, and interior trim removal/installation.
Wheel Tire Service:
Information on wheel bearing replacement, tire rotation, and specifications for wheel alignment.
Wiring Diagrams:
Extensive, system-by-system wiring diagrams for all major electrical components, enabling precise troubleshooting of electrical faults.
Emission Controls:
Details on catalytic converters, EGR valves, O2 sensors, and the evaporative emission control system, including diagnostic and repair procedures.
Technical Depth
Technical Depth:
Comprehensive from basic maintenance to advanced engine and transmission rebuilds. Includes detailed specifications, torque values, and wiring diagrams.
Diagnostic Tools Coverage:
Covers basic diagnostic tool usage, multimeter testing, and often references specific Chrysler diagnostic codes (e.g., OBDI) for the era.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, clear text and diagrams, suitable for printing.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Completeness
Manual Completeness:
Comprehensive, covering all aspects of repair and maintenance for the specified model years, engine options, and trim levels within the first generation.
5-speed Manual Transmission (NV3500), 4-speed Automatic Transmission (A500, A518, A618 - especially with V8 engines).
Features
Transmission Features:
Includes detailed procedures for clutch service, transmission fluid changes, seal replacement, and overhaul for both manual and automatic units.
📐 Dimensions
Exterior
Wheelbase Options:
Short bed (approx. 112 inches), Long bed (approx. 124 inches).
Weights
Curb Weight Range:
Approximately 3,000 lbs to 4,000 lbs depending on configuration and engine.
🛡️ Safety Features
Ratings
Safety Ratings:
Information on passive safety features typical for the era; specific NHTSA/IIHS ratings for this generation are limited but would be covered for component safety.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS) available on some models, particularly later ones and those with larger engines.
Passive Features
Passive Safety Features:
Seat belts (lap and shoulder belts), crumple zones integrated into the chassis and body structure.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM radio with cassette player standard. Optional CD player available on higher trim levels or later model years. Speaker placement varied by cab configuration.
Driver Assistance
Driver Assistance Features:
Limited by era; primary driver assistance would be ABS on models equipped. No electronic stability control or advanced traction control systems.
Connectivity
Connectivity Features:
No modern connectivity features such as Bluetooth or USB ports. Vehicle systems are primarily electromechanical.
🔧 Maintenance
Service Intervals
Recommended Oil Change Interval:
Typically every 3,000 to 5,000 miles, or 6 months, depending on driving conditions and oil type. Check manual for specific recommendations.
Fluid Specifications
Engine Oil Specification:
API Service SG/SH or higher. Viscosity typically 5W-30 or 10W-30 depending on climate (e.g., SAE 5W-30 for temperatures below 0°F, SAE 10W-30 for temperatures above 0°F).
Coolant Specification:
Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water. Check for Mopar specifications for the era (e.g., Mopar Antifreeze/Coolant).
Transmission Fluid Specification Automatic:
Chrysler ATF+3 (or equivalent) for A500/A518/A618 transmissions. Check manual for exact specification based on transmission model.
Transmission Fluid Specification Manual:
API GL-4 or GL-5 gear lubricant, typically SAE 75W-90 or SAE 80W-90 for manual transmissions. Refer to specific transmission type in manual.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Issues Electrical:
Corrosion in wiring harnesses, faulty grounds, intermittent gauge operation, issues with power windows/locks if equipped.
Common Issues Engine:
Head gasket leaks (especially on earlier 4-cylinders), exhaust manifold cracks, oil leaks from valve covers and oil pan gaskets, distributor issues, timing chain wear.
Common Issues Transmission:
Torque converter lock-up issues in automatics, worn synchros in manuals, potential leaks from seals and gaskets.
Common Issues Suspension:
Worn ball joints and tie rod ends, sagging leaf springs, worn control arm bushings.
Common Issues Chassis:
Frame rust (depending on climate/care), exhaust system corrosion.
Fluid Capacities
Engine Oil Capacity:
Varies by engine: approx. 5 quarts (4.7L) for 4-cylinders, 5.5 quarts (5.2L) for V6 engines, 6 quarts (5.7L) for 5.2L V8. Always verify with dipstick.
Cooling System Capacity:
Approx. 12-14 quarts (11.4-13.3L) depending on engine and radiator size.
Transmission Fluid Capacity Automatic:
Approx. 3.5-4 quarts (3.3-3.8L) for A500, A518, A618 transmissions for a fluid change. Total capacity higher.
Fuel Tank Capacity:
Typically 20-23 gallons (75.7-87.1L) depending on cab and bed configuration.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Dodge, as part of Chrysler, has a long history in trucks, dating back to the Power Wagon. The Dakota aimed to capture a growing market for smaller, more fuel-efficient trucks.
Model Evolution
Model Evolution:
The first generation Dakota (1987-1996) was a significant entry, establishing Dodge as a player in the compact truck segment. It was redesigned in 1997 for its second generation.
Production
Production Locations:
Primarily manufactured at the Warren Truck Assembly Plant in Warren, Michigan.
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for this generation are not prominently recalled, the Dakota was generally well-received for its value and capability in the compact truck market, often praised for its available V8 power which was a class-exclusive for much of its early run.
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