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Dodge Dakota 1991 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Dakota Year: 1991 Body Style: Compact Pickup Truck Generation: First Generation (1987-1996) Codes Chassis Code: ND (Second Gen chassis code, but ND is...
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Dodge Dakota 1991 Full Service Repair ManualDodge Dakota 1991 Full Service Repair ManualDodge Dakota 1991 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Dakota
Year:
1991
Body Style:
Compact Pickup Truck
Generation:
First Generation (1987-1996)
Codes
Chassis Code:
ND (Second Gen chassis code, but ND is common for first gen too)
👋 Introduction
Market Position
Description:
The Dodge Dakota was a pioneering compact/mid-size pickup truck, bridging the gap between smaller Japanese imports and full-size American trucks. It offered V6 and V8 engine options uncommon in its class at the time.
Competitive Analysis
Competitors:
Ford Ranger, Chevrolet S-10/S-15 Sonoma, Nissan Hardbody, Toyota Pickup.
Key Features
Vehicle Attributes:
Available in Regular Cab and Club Cab configurations, choice of bed lengths, powerful V8 option for a compact truck.
Manual Value
Benefit To Owner:
Empowers owners to perform complex repairs and maintenance, saving money and ensuring vehicle longevity.
📋 Manual Details
Coverage Areas
Description:
Comprehensive service, repair, maintenance, and troubleshooting for the 1991 Dodge Dakota.
Page Count
Estimated Pages:
Varies by publisher; typically 700-1000+ pages for a full service manual.
Manual Type
Type:
Full Service & Repair Manual
Language
Language:
English
Format
Format:
Physical Book (likely)
📖 Manual Coverage
Systems Covered
Engine:
All engine types, including disassembly, inspection, repair, and reassembly.
Transmission:
Manual and automatic transmission service, overhaul, and adjustment.
Drivetrain:
Rear-wheel drive system, driveshaft, differential, and axle service.
Suspension:
Front and rear suspension components, alignment, and steering system.
Brakes:
Front and rear brake systems (disc/drum), hydraulic systems, and parking brake.
Electrical:
Complete electrical system diagnosis, wiring diagrams, lighting, ignition, starting, charging, and accessories.
Fuel System:
Fuel delivery, fuel injection (if applicable), carburetor service (for older models), fuel tank, and lines.
Cooling System:
Radiator, water pump, thermostat, fan, and cooling system maintenance.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, and pipe replacement.
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair.
Body And Frame:
Body panel repair, door mechanisms, interior trim, glass replacement, and chassis inspection.
Diagnostic Troubleshooting:
Systematic diagnostic procedures and troubleshooting guides for common and uncommon issues.
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, spark plug service, coolant flushes, and routine inspections.
Component Replacement:
Step-by-step instructions for replacing major and minor components.
Rebuilding Procedures:
Detailed instructions for engine, transmission, and other major unit rebuilds.
Torque Specifications:
Critical torque values for all fasteners and critical assemblies.
Alignment Specifications:
Wheel alignment angles and specifications.
Troubleshooting Charts:
Flowcharts and tables to diagnose problems based on symptoms.
Wiring Diagrams:
Complete and detailed electrical wiring schematics for all vehicle systems.
Technical Depth
Depth:
In-depth, from basic maintenance to complete engine and transmission rebuilds.
📊 Manual Specifications
File Format
Searchable Text:
Typically yes for PDF versions; not applicable for printed.
Print Quality
Quality:
Professional printing with clear diagrams and text (for physical copies).
Binding Type
Type:
Perfect binding or spiral binding (for printed copies).
Paper Type
Type:
Durable paper stock suitable for workshop use.
⚙️ Engine Specifications
Primary Engine
Engine 2.5L I4:
2.5L (153 cu in) Chrysler Slant-Four I4 (G-Engine)
Engine 3.9L V6:
3.9L (239 cu in) Chrysler Magnum V6
Engine 5.2L V8:
5.2L (318 cu in) Chrysler Magnum V8 (late in model year availability)
Performance 2.5L
Horsepower 2.5L:
Approx. 100-114 hp (depending on configuration)
Torque 2.5L:
Approx. 130-145 lb-ft
Performance 3.9L
Horsepower 3.9L:
Approx. 125-130 hp
Torque 3.9L:
Approx. 190-195 lb-ft
Performance 5.2L
Horsepower 5.2L:
Approx. 170-175 hp
Torque 5.2L:
Approx. 250-255 lb-ft
Fuel System
Injection Type:
Electronic Fuel Injection (EFI) for V6/V8, Throttle Body Injection (TBI) for 2.5L I4.
Fuel Type:
Unleaded Gasoline
Engine Management
ECM:
Chrysler's reliable microcomputer engine control (MEC) systems.
🔧 Transmission
Standard
Transmission 5 Speed Manual:
A500/A518 variants (for V6/V8), Getrag A500 (for 2.5L I4).
Optional
Transmission 3 Speed Automatic:
TorqueFlite A904 (primarily for 2.5L I4).
Transmission 4 Speed Automatic:
A500/A518 4-speed overdrive automatic (for V6/V8).
Features
Overdrive:
Available on 4-speed automatic transmissions.
Fluid Type
Automatic Transmission Fluid:
Chrysler ATF+3 (or equivalent specification like Dexron-III for older models)
Manual Transmission Fluid:
GL-4 gear oil (specific weight varies).
📐 Dimensions
Exterior Short Bed
Wheelbase Short Bed:
112 inches
Exterior Long Bed
Wheelbase Long Bed:
124 inches
Exterior Bed Length
Short Bed Length:
6 feet (72 inches)
Long Bed Length:
7.5 feet (90 inches)
Weights
Curb Weight Range:
Approximately 3,000 - 3,700 lbs (depending on configuration and engine)
Towing Capacity:
Varies by engine and configuration, up to approximately 6,000 lbs for V8 models.
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
The 1991 Dakota was not extensively crash-tested by NHTSA to modern standards; rollover resistance ratings are not readily available.
Active Features
Brakes Type:
Front disc, rear drum brakes standard. Optional rear anti-lock brakes (RABS) on some models.
Passive Features
Seatbelts:
Lap and shoulder belts for front occupants; lap belts for center passenger and rear passengers (if equipped).
Driver Airbag:
Not standard on all trims; optional on some models, but not universally equipped.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio with cassette player. Optional premium sound systems available.
Driver Assistance
Cruise Control:
Optional on most models.
Connectivity
Early Features:
Limited by 1991 standards; primarily mechanical systems and basic electrical conveniences.
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 3,000 miles or 3 months, whichever comes first (typical for this era).
Service Intervals Filters
Oil Filter Part Number:
Commonly Mopar equivalent to Fram PH5 or equivalent (consult manual for exact fitment).
Service Intervals Spark Plugs
Spark Plug Replacement:
Every 30,000 miles (typical for this era; refer to manual for specific plugs per engine).
Service Intervals Coolant
Coolant Flush Interval:
Every 30,000 miles or 2 years.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-30 or 5W-30 (depending on climate; consult manual).
Engine Oil Capacity:
4.5-5.5 quarts (depending on engine; typically 5 quarts for V6/V8).
Coolant Type:
Ethylene Glycol based coolant (e.g., Mopar Antifreeze/Coolant, or equivalent meeting Chrysler MS-4 specification).
Brake Fluid Type:
DOT 3 Brake Fluid.
Known Issues
Common Problems Engine Management:
Fuel pump issues, intermittent sensor failures (e.g., MAP, TPS), EGR valve issues.
Common Problems Transmission:
A500/A518 automatic transmission torque converter clutch issues, valve body problems.
Common Problems Rust:
Frame rust, especially in areas exposed to road salt. Cab corners and rocker panels are also susceptible.
Common Problems Electrical:
Aging wiring harness insulation, dashboard instrument cluster issues, blower motor resistors failing.
Common Problems Suspension:
Worn ball joints, tie rod ends, and sway bar links due to age and mileage.
📚 Vehicle History
Brand Heritage
Dodge Truck History:
Dodge has a long history of producing robust and capable trucks, starting with the Dodge Power Wagon.
Model Evolution
Dakota Introduction:
The Dodge Dakota was introduced for the 1987 model year as a groundbreaking compact pickup, designed to offer greater utility and power than other compacts of its era.
Production
Manufacturing Plant:
Warren Truck Assembly Plant, Warren, Michigan, and Saltillo Truck Plant, Saltillo, Mexico.
Model Year Updates 1991
Updates For 1991:
Minor styling tweaks, potentially revised options or trim levels. Introduction of the 5.2L V8 engine option late in the model year for some configurations.
🏆 Awards & Recognition
Recognitions
Contemporary Reviews:
The Dakota was generally well-received for its innovative positioning and available V8 power, often earning praise for its V8 engine's performance in the compact truck segment.
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