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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...
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SKU: 446613
Dodge Dakota 1987-1996 Workshop Service Manual for Repair
🏷️ 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; 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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