Dodge Dakota 1991 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Dakota Year: 1991 Codes Vehicle Platform: Chrysler AD platform 👋 Introduction Market Position Vehicle Segment: Compact Pickup Truck Target Audience: DIY mechanics, fleet...

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Type: Truck

Vendor:

Sku: 405910

Tags: 1991 Cars Dakota Dodge Misc Truck

Product variants

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Dakota

Year:

Codes

Vehicle Platform:

Chrysler AD platform

👋 Introduction

Market Position

Vehicle Segment:

Compact Pickup Truck

Target Audience:

DIY mechanics, fleet maintenance, professional repair shops.

Competitive Analysis

Key Competitors:

Ford Ranger, Chevrolet S-10, Nissan Hardbody.

Key Features

Vehicle Strengths:

Compact size, maneuverability, optional V6 power, available 4WD.

Manual Value Proposition:

Provides in-depth technical knowledge essential for maintaining and repairing this classic Dodge model.

📋 Manual Details

Coverage Areas

All Models Engines Trims Transmissions:

Page Count

Estimated Pages:

Over 1000 pages (typical for full workshop manuals of this era)

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, diagnosis, and repair of all engine variants.

Fuel System:

Fuel injection systems (MPI, TBI where applicable), fuel pumps, lines, filters, evaporative emission controls.

Ignition System:

Distributor, ignition coil, spark plugs, wiring, electronic ignition control.

Cooling System:

Radiator, fan, water pump, thermostat, coolant specifications, hoses, diagnosis.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, O2 sensors, emissions.

Transmission Manual:

Service, repair, and overhaul procedures for manual transmissions.

Transmission Automatic:

Service, repair, and overhaul procedures for automatic transmissions.

Drivetrain Rear Wheel Drive:

Driveshafts, U-joints, rear axle assembly, differential service.

Drivetrain Four Wheel Drive:

Transfer case operation, service, and repair; front driveshafts and axles.

Suspension Front:

Independent front suspension, control arms, ball joints, springs, shocks, steering linkage.

Suspension Rear:

Leaf spring suspension, shock absorbers, axle housing.

Brakes Hydraulic:

Master cylinder, brake lines, hoses, calipers, wheel cylinders, brake fluid specifications.

Brakes Parking:

Parking brake system operation and adjustment.

Steering:

Power steering system, steering gear, steering column, alignment procedures.

Electrical System Charging:

Alternator, voltage regulator, battery, wiring.

Electrical System Starting:

Starter motor, starter solenoid, ignition switch.

Lighting System:

Headlights, taillights, interior lighting, fuses, relays.

Instrument Panel:

Gauges, warning lights, switches, dashboard components.

Body Exterior:

Body panel removal/installation, doors, hood, tailgate, glass, trim.

Body Interior:

Seats, upholstery, carpeting, dashboard, interior trim panels.

HVAC System:

Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant handling.

Cruise Control:

Operation and troubleshooting.

Procedures Included

Routine Maintenance:

Oil changes, fluid checks, filter replacements, lubrication.

Troubleshooting Diagnostics:

Systematic diagnostic procedures for common and uncommon issues, including symptom-based troubleshooting.

Component Removal Installation:

Detailed step-by-step instructions for removing and installing major and minor components.

Engine Rebuilding:

Full engine teardown, inspection, machining recommendations, and reassembly procedures.

Transmission Overhaul:

Complete disassembly, inspection, repair, and reassembly of both manual and automatic transmissions.

Brake System Service:

Brake pad/shoe replacement, caliper/wheel cylinder service, rotor/drum machining/replacement, bleeding procedures.

Suspension Alignment:

Front and rear suspension alignment specifications and procedures.

Electrical Component Testing:

Testing of motors, switches, sensors, and other electrical components using multimeters and diagnostic tools.

Wiring Diagrams:

Detailed electrical wiring diagrams for all systems.

Torque Specifications:

Crucial torque values for all fasteners and critical components.

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and advanced DIY enthusiasts.

Diagnostic Tools:

References diagnostic trouble codes (DTCs) and provides diagnostic procedures using standard automotive tools.

Schematics:

Includes detailed mechanical and electrical schematics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable if a high-quality scan/OCR process was used.

Print Quality

Print Quality Estimation:

High-resolution scans suitable for clear printing of text and diagrams.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1:

2.5L (150 cu in) Chrysler 4-cylinder (Technically a Mitsubishi design, licensed by Chrysler)

Engine 1 Hp:

Approx. 100-125 hp

Engine 1 Torque:

Approx. 135-150 lb-ft

Engine 2:

3.9L (239 cu in) Chrysler Magnum V6

Engine 2 Hp:

Approx. 125-140 hp

Engine 2 Torque:

Approx. 180-200 lb-ft

Performance

Fuel Delivery:

Multi-point Fuel Injection (MPI) for V6, Throttle Body Injection (TBI) for 4-cylinder (depending on specific application within 1991 models).

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

Approx. 20-22 gallons

🔧 Transmission

Standard

Transmission Std:

Getrag 360 5-speed manual (likely for V6 RWD/4WD)

Optional

Transmission Opt 1:

A500 4-speed automatic (likely for V6)

Transmission Opt 2:

Manual transmission (likely Aisin AX15) for 4-cylinder engines

Features

Transmission Fluid Type Auto:

Chrysler ATF+3 (or equivalent, check manual for exact spec)

Transmission Fluid Type Manual:

Gear oil, SAE 75W-90 (check manual for exact spec)

📐 Dimensions

Exterior

Wheelbase:

112.1 inches (standard cab)

Bed Length Options:

6.5 ft and 8 ft

Weights

Curb Weight Range:

Approx. 3,300 - 4,000 lbs (depending on configuration)

🛡️ Safety Features

Ratings

NHTSA Crash Test Data:

Limited data available for this era; focus on passive safety features.

Active Features

Anti-lock Braking System (ABS) available as an option on rear wheels.

Passive Features

Seat Belts:

Three-point front seat belts.

Airbags:

No airbags typically equipped on 1991 models.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with cassette player, optional premium sound system.

Driver Assistance

Cruise Control:

Available as an option, electronically controlled.

Connectivity

Auxiliary Inputs:

None standard; aftermarket solutions would be required.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000 miles or 3 months (refer to manual for exact mileage/time based on driving conditions).

Transmission Service Interval Auto:

Fluid and filter change every 30,000-60,000 miles (check manual).

Transmission Service Interval Manual:

Gear oil change typically every 60,000 miles.

Coolant Flush Interval:

Every 30,000 miles or 2 years.

Fluid Specifications

Engine Oil Spec:

API SG or higher, SAE 10W-30 (check manual for variations by temperature).

Brake Fluid Spec:

DOT 3 SAE J1703

Power Steering Fluid Spec:

Mopar Power Steering Fluid or equivalent (Dexron III may be substituted but check manual).

Known Issues

Common Wear Items:

Leaf springs (sagging), U-joints (wear), rust (common on older trucks, especially wheel wells and cab corners), dashboard cracks (UV exposure).

Engine Specific Notes:

Early Magnum V6s can have lifter noise; 4-cylinder engines are generally robust but can suffer from oil consumption if not maintained.

Transmission Specific Notes:

Automatic transmissions (A500) can develop issues with torque converter lock-up and solenoid failure. Manual transmissions are generally durable.

📚 Vehicle History

Brand Heritage

Dodge Truck Division:

Dodge has a long history of producing trucks, with the Ram line being iconic.

Model Evolution

Dakota Introduction:

The Dodge Dakota was introduced for the 1987 model year as a compact/mid-size pickup, filling a gap in Chrysler's truck lineup. The 1991 model is part of the first generation (1987-1996).

Production

Manufacturing Location:

Warren Truck Assembly Plant, Warren, Michigan, USA.

🏆 Awards & Recognition

Recognitions

Automotive Press Reviews:

Received favorable reviews for its handling and V6 engine for the compact truck class upon introduction. Recognized for its balance of capability and maneuverability.