1991 Dodge Dakota Service and Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Dakota Year: 1991 Codes Vehicle Code Name: AN Generation First Generation Start Year: 1987 First Generation End Year: 1996 Current Generation Model Year:...

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Type: Truck

Vendor:

Sku: 456375

Tags: 1991 Cars Dakota Dodge Misc Truck

Product variants

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Dakota

Year:

Codes

Vehicle Code Name:

Generation

First Generation Start Year:

First Generation End Year:

Current Generation Model Year:

👋 Introduction

Market Position

Segment:

Compact Pickup Truck

Key Selling Point:

Compact size with car-like ride quality and available V6 power

Competitive Analysis

Direct Competitors:

Ford Ranger, Chevrolet S-10/GMC Sonoma, Toyota Tacoma (first generation was later), Nissan Hardbody

Key Features

Body Styles:

Regular Cab, Extended Cab

Drivetrain Options:

Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD)

Powertrain Variety:

Offered a range of engine options including efficient 4-cylinders and powerful V6s.

📋 Manual Details

Coverage Areas

Primary Coverage:

All models and all repairs A-Z

Diagnostic Coverage:

Comprehensive diagnostic procedures

Maintenance Coverage:

Routine maintenance and preventative care

Repair Coverage:

Detailed step-by-step repair instructions

Specifications Coverage:

Vehicle-specific technical specifications

Page Count

Estimated Page Count:

Over 1000 pages (typical for comprehensive service manuals of this era)

Manual Type

Manual Type:

Service and Repair Manual

Origin Of Manual:

Factory-authorized technician manual

Language

Language:

English

Format

Format:

Printed

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, component replacement, timing, seals, gaskets

Engine Fuel System:

Fuel injection, fuel pump, injectors, pressure regulator, emissions control

Engine Ignition System:

Spark plugs, ignition coils, distributor, timing control

Transmission Manual:

Clutch, gearbox overhaul, gear ratios, shifting mechanisms

Transmission Automatic:

Transmission overhaul, torque converter, hydraulic control, valve body

Drivetrain:

Driveshafts, U-joints, differential, axles

Suspension:

Front and rear suspension, springs, shocks, control arms, bushings

Steering:

Power steering system, steering gear, linkage, column

Brakes:

Front and rear brakes (disc/drum), hydraulic system, master cylinder, calipers, wheel cylinders, parking brake

Electrical System:

Battery, charging system, starter, lighting, accessories, wiring diagrams

Body And Frame:

Body panel removal, repair, structural components, chassis

HVAC:

Heating, ventilation, and air conditioning system diagnosis and repair

Dashboard And Instruments:

Instrument cluster, gauges, warning lights, switchgear

Restraint Systems:

Seat belts, airbags (if applicable for the year, though less common for 1991)

Procedures Included

General Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, lubrication

Engine Diagnostics:

Troubleshooting engine performance issues, misfires, starting problems

Transmission Repair:

Complete rebuild procedures for both manual and automatic transmissions

Brake Service:

Brake pad/shoe replacement, rotor/drum resurfacing, hydraulic system bleeding

Electrical Troubleshooting:

Using wiring diagrams to diagnose electrical faults

Engine Rebuild:

Detailed instructions for engine disassembly, inspection, and reassembly

Suspension Component Replacement:

Ball joints, tie rods, control arms, shock absorbers

HVAC System Repair:

Component replacement (compressor, evaporator, condenser), refrigerant handling (with caution for era's refrigerants)

Wheel Alignment:

Specifications for caster, camber, and toe angles

Body Repair:

Dent repair, panel replacement, rust treatment

Technical Depth

Depth Level:

Complete vehicle overhaul and repair

Diagnostic Capability:

Advanced diagnostic procedures and troubleshooting trees

Torque Specifications:

Detailed torque values for all critical fasteners

Clearances And Tolerances:

Specifications for engine internal clearances, bearing play, etc.

Wiring Diagrams:

Comprehensive, high-quality electrical wiring diagrams for all systems

📊 Manual Specifications

File Format

File Format:

Printed Document

Print Quality

Print Quality:

Professional printer quality with clear diagrams and text

Binding Type

Binding Type:

Likely perfect bound or spiral bound for ease of use in a workshop setting

Paper Type

Paper Type:

Durable paper stock designed for workshop environments

⚙️ Engine Specifications

Primary Engine

Base Engine 1991:

2.5L 8-valve OHV Inline-4 (4-250)

Base Engine Horsepower 1991:

~100 hp @ 4400 rpm

Base Engine Torque 1991:

~135 lb-ft @ 2400 rpm

Performance

Optional Engine 1991:

3.0L 12-valve OHV V6 (6G72)

Optional Engine Horsepower 1991:

~143-150 hp @ 4800-5000 rpm

Optional Engine Torque 1991:

~160-170 lb-ft @ 2400-3000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Recommended Fuel:

Unleaded gasoline (Octane rating as per owner's manual)

Engine Management

ECU Type:

Chrysler's proprietary engine control unit (ECU)

🔧 Transmission

Standard

Standard Transmission Type:

5-speed Manual

Optional

Optional Transmission Type:

3-speed Automatic (A500/42RH) or 4-speed Automatic (A518/46RH) on some V6 models

Features

Transfer Case 4Wd:

Part-time 4WD transfer case with manual or automatic (NP231/NP236 variants)

📐 Dimensions

Exterior

Wheelbase Regular Cab:

~109.6 inches

Wheelbase Extended Cab:

~124.5 inches

Bed Lengths:

Short bed (~6.5 ft), Long bed (~8 ft)

Weights

Curb Weight Range:

~3000-3700 lbs depending on configuration

Towing Capacity Range:

~2000-4500 lbs depending on engine and configuration

🛡️ Safety Features

Ratings

Crash Test Results 1991:

Limited public data available for this era; NHTSA ratings not as comprehensive as modern standards.

Active Features

Braking System:

Front disc, rear drum brakes. Optional rear ABS on some models.

Passive Features

Seat Belts:

Standard lap and shoulder belts

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM radio with cassette player, optional CD player.

Speakers:

Basic speaker configurations, typically 2 or 4 speakers.

Driver Assistance

Rear Anti-lock Braking System (ABS) available on select models/trims.

Connectivity

Connectivity Features:

None (pre-dates modern connectivity features like Bluetooth or USB).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000 miles or 3 months (as per original recommendation for this era).

Transmission Fluid Change:

Every 30,000-60,000 miles depending on use and transmission type.

Spark Plug Replacement:

Refer to manual; generally around 30,000 miles for conventional plugs.

Fluid Specifications

Engine Oil Viscosity:

Typically 5W-30 or 10W-30 for the 4-cylinder, 10W-30 for the V6 (check manual for precise spec).

Engine Coolant:

Ethylene Glycol based coolant (e.g., Mopar Antifreeze/Coolant) - check capacity in manual.

Brake Fluid Type:

DOT 3 brake fluid

Power Steering Fluid:

ATF+3 or equivalent power steering fluid (check manual).

Known Issues

Common Issues 1991:

Rust (especially wheel wells and frame), potential for ignition system issues (e.g., distributor cap/rotor), HVAC blower motor resistor failure, minor electrical gremlins.

Engine Performance Notes:

4-cylinder can feel underpowered when loaded or at altitude. V6 offers significantly better performance.

📚 Vehicle History

Brand Heritage

Manufacturer History:

Dodge, a division of Chrysler Corporation, has a long history of producing robust vehicles, including trucks and performance cars.

Model Evolution

First Generation Intro:

The Dodge Dakota was introduced for the 1987 model year, designed to fill a gap between smaller Japanese compact trucks and larger American full-size pickups.

1991 Update Significance:

The 1991 model represents a mid-cycle refresh for the first generation, featuring updated styling, interior refinements, and powertrain improvements.

Production

Assembly Locations:

Primarily Warren Truck Assembly Plant, Warren, Michigan.

🏆 Awards & Recognition

Recognitions

Historical Recognition:

While specific 'awards' for the 1991 model are not prominently documented, the Dakota line was recognized for its utility and the introduction of a V6 in a compact truck segment.