check engine CHRYSLER TOWN AND COUNTRY 2002 Service Manual

STANDARD PROCEDURE - CHECKING
CRANKSHAFT END PLAY
(1) Mount a dial indicator to a stationary point at
rear of engine. Locate the probe perpendicular
against the flywheel (Fig. 35).
(2) Move the crankshaft all the way to the front of
its travel.
(3) Zero the dial indicator.
(4)
Move the crankshaft all the way to the rear and
read dial indicator. For crankshaft end play clearances
(Refer to 9 - ENGINE - SPECIFICATIONS).
REMOVAL
(1) Remove engine from vehicle (Refer to 9 -
ENGINE - REMOVAL).
(2) Mount engine on an engine stand.
(3) Drain engine oil and remove oil filter.
(4) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(5) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(6) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(7) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(8) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(9) Remove flywheel.
(10) Remove rear main bearing support/adapter
plate retaining bolts and remove adapter plate (Fig.
36).
Fig. 35 CHECKING CRANKSHAFT END PLAY
1 - DIAL INDICATOR
2 - ADAPTER PLATE
3 - REAR MAIN BEARING SUPPORT
4 - SEALING RING
5 - SEALING RING
6 - ALIGNMENT PIN
7 - CRANKSHAFT
8 - RELUCTOR WHEEL
9 - RELUCTOR WHEEL RETAINING BOLT
10 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
11 - FLYWHEEL
12 - FLYWHEEL BOLTSFig. 36 REAR MAIN BEARING SUPPORT
1 - ADAPTER PLATE
2 - REAR MAIN BEARING SUPPORT
3 - CRANKSHAFT
4 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
RGENGINE9a-31
CRANKSHAFT (Continued)
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INSPECTION
The cylinder walls should be checked for out-of-
round and taper with a dial bore gauge. The cylinder
bore out-of-round is 0.100 mm (.0039 in.) maximum
and cylinder bore taper is 0.100 mm (.0039 in.) max-
imum. If the cylinder walls are badly scuffed or
scored, new liners should be installed and honed, and
new pistons and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 42). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from the bottom bore.
INSTALLATION
(1) Carefully clean liner and engine block, and
degrease the engine block where it comes into contact
with the liners. Install the liners in the engine block
as shown, rotating them back and forth by 45É in
order to guarantee correct positioning (Fig. 43).
(2) Measure the liner recess relative to block deck
with a dial indicator mounted on a special tool
VM-1010 A.All the measurements must be taken
on high pressure pump side of engine block..
Zero dial gauge on block deck.
(3) Move dial gauge to cylinder liner record read-
ing on dial gauge.
(4) Remove liner and special tool.
(5) Then select the correct shim thickness to give
proper protrusion (0.01 - 0.06 mm).
(6) Fit the shim and the O-rings onto the liner.
(7) Lubricate the lower liner location in the block.
(8) Fit the liners in the crankcase making sure
that the shim is positioned correctly in the seat. Lock
the liners in position using special tool (VM.1076)
and bolts (Fig. 44). Clean the residual LOCTITE on
the upper surface of the block deck.
(9) Recheck the liner protrusion. It should be 0.01
- 0.06 mm.
(10) Reassemble engine.
(11) Install engine in vehicle.
Fig. 42 LINER INSPECTION
Fig. 43 LINER INSTALLATION
1 - CYLINDER LINER
2 - SHIMS
3 - O-RINGS
4 - BLOCK LEDGE
5 - ENGINE BLOCK
Fig. 44 LINER CLAMP LOCATION
1 - ENGINE BLOCK
2 - LINER RETAINER VM.1076
3 - CYLINDER LINER
9a - 34 ENGINERG
CYLINDER LINERS (Continued)
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(10) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(11) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(12) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Install air cleaner housing.
(14) Connect negative battery cable.
PISTON & CONNECTING ROD
DESCRIPTION
The pistons are of a free floating design. Oil jets in
the engine block lubricate and cool the piston and pin
assembly. The connecting rods have a pressed in
place wrist pin bushing which is lubricated by the oil
jets (Fig. 48).
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 in.) from bottom of
cylinder bore (Fig. 49). Check gap with feeler gauge.
Top compression ring gap .30 to .45mm (.0118 to
.0177 in.). Second compression ring gap .30 to .45mm(.0118 to .0177 in.). Oil control ring gap .25 to .50mm
(.0098 to .0196 in.).
(2) If ring gaps exceed dimension given, new rings
or cylinder liners must be fitted. Keep piston rings in
piston sets.
(3) Check piston ring to groove clearance (Fig. 50).
Top compression ring gap .080 to .130mm (.0031 to
.0051 in.). Second compression ring gap .070 to
.110mm (.0027 to .0043 in.). Oil control ring gap .040
to .080mm (.0015 to .0031 in.).
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
Fig. 47 VACUUM PUMP COMPONENTS
1 - VACUUM PUMP BODY
2 - VACUUM PUMP BLADE TAPERED EDGE
3 - VACUUM PUMP BLADE
Fig. 48 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
9a - 36 ENGINERG
INTERNAL VACUUM PUMP (Continued)
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PISTON RING - REMOVAL
(1) ID mark on face of top and second piston rings
must point toward piston crown.
(2) Using a suitable ring expander, remove top and
second piston rings (Fig. 52).
(3) Remove upper oil ring side rail, lower oil ring
side rail and then the oil expander from piston.
(4) Carefully clean carbon from piston crowns,
skirts and ring grooves ensuring the 4 oil holes in
the oil control ring groove are clear.
INSPECTION
PISTONS
(1) Piston Diameter: Size: 91.912-91.928mm
(3.6185-3.6192 in.) Maximum wear limit .05mm
(.0019 in.).
(2) Check piston pin bores in piston for roundness.
Make 3 checks at 120É intervals. Maximum out of
roundness .05mm (.0019in.).
(3) The piston diameter should be measured
approximately 15 mm (.590 in.) up from the base.
(4) Skirt wear should not exceed 0.1 mm (.00039
in.).
(5) The clearance between the cylinder liner and
piston should not exceed 0.065-0.083 mm
(.0025-.0032 in.).
(6) Make sure the weight of the pistons does not
differ by more than 5 g.
CONNECTING RODS
(1) Assemble bearing shells and bearing caps to
their respective connecting rods ensuring that the
serrations on the cap and reference marks are
aligned.
(2) Tighten connecting cap bolts to 29 N´m (21 ft.
lbs.) plus 60É.
(3) Without loosening connecting rod bolts, tighten
all bolts to 88N´m.(4) Check and record internal diameter of crank
end of connecting rod.
NOTE: When changing connecting rods, all four
must have the same weight and be stamped with
the same number. Replacement connecting rods
will only be supplied in sets of four.
Connecting rods are supplied in sets of four since
they all must be of the same weight category. Max
allowable weight difference is 5 gr.
NOTE: On one side of the big end of the con-rod
there is a two-digit number which refers to the
weight category. On the other side of the big end
there is a four digit number on both the rod and the
cap. These numbers must both face the injection
pump side of the block (Fig. 53). Lightly heat the
piston in oven. Insert piston pin in position and
secure it with provided snap rings.
The Four digit numbers marked on con rod
big end and rod cap must be on the same side
as the injection pump (Fig. 53).After having
coated threads with Molyguard, tighten con rod bolts
to 29 N´m (21 ft. lbs.) plus 60É.
PISTON PINS
(1) Measure the diameter of piston pin in the cen-
ter and both ends.
(2) Piston pin diameter is 29.992 to 29.996mm
(1.1807 to 1.1809 in.).
Fig. 52 PISTON RINGS - REMOVAL/INSTALLATION
Fig. 53 CONNECTING ROD IDENTIFICATION
1 - SMALL END OF CONNECTING ROD
2 - 2 DIGIT NUMBER LOCATION
3 - 4 DIGIT NUMBER LOCATION
9a - 38 ENGINERG
PISTON & CONNECTING ROD (Continued)
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INSTALLATION
PISTON PIN INSTALLATION
(1) Secure connecting rod in soft jawed vice.
(2) Lubricate piston pin and piston with clean
engine oil.
(3) Position piston on connecting rod (Fig. 54).
CAUTION: Ensure arrow on piston crown and the
bearing cap numbers on the connecting rod are on
the opposite side.
(4) Install piston pin (Fig. 54).
(5) Install clips in piston to retain piston pin (Fig.
54).(6) Remove connecting rod from vice.
PISTON RINGS - INSTALLATION
(1) Install rings on the pistons using a suitable
ring expander (Fig. 55).
(2) Top compression ring is tapered and chromium
plated. The second ring is of the scraper type and
must be installed with scraping edge facing bottom of
the piston. The third is an oil control ring. Ring gaps
must be positioned, before inserting piston into the
liners, as follows.
(3) Top ring gap must be positioned at the #3 posi-
tion (looking at the piston crown from above) (Fig.
56).
(4) Second piston ring gap should be positioned at
the #1 position (Fig. 56).
(5) Oil control ring gap should be positioned at the
#2 position (Fig. 56).
(6) When assembling pistons check that compo-
nents are installed in the same position as before dis-
Fig. 54 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
Fig. 55 PISTON RINGS-INSTALLATION
Fig. 56 PISTON RING GAP LOCATION
3 - TOP COMPRESSION RING GAP POSITION
1 - SECOND COMPRESSION RING GAP POSITION
2 - OIL CONTROL RING GAP POSITION
RGENGINE9a-39
PISTON & CONNECTING ROD (Continued)
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(3) Install oil pump retaining bolts (Fig. 71).
Torque bolts to 10.8N´m.
(4) Install crankshaft sprocket (Fig. 71). Torque
bolts to 10.8N´m.
(5) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(6) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(8) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(9) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Connect negative battery cable.
INSTALLATION
(1) Lubricate o-ring on oil pump pickup tube with
engine oil.
(2) Install pickup tube in engine block and install
retaining bolt (Fig. 72). Torque bolt to 32.4N´m.
(3) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(4) Refill engine oil to proper level.
(5) Connect negative battery cable.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The oil pressure switch is located on the right side
of the engine block. The switch screws into the
engines main oil gallery (Fig. 73).
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Disconnect oil pressure switch electrical con-
nector (Fig. 73).
(4) Remove oil pressure switch from engine block.
INSTALLATION
(1) Apply MopartThread Sealant to the switch
threads.
(2) Install oil pressure switch in engine block.
(3) Connect oil pressure switch electrical connector
(Fig. 73).(4) Lower vehicle.
(5) Start engine and check for leaks.
(6) Check and adjust oil level as necessary.
OIL TEMPERATURE SENSOR
DESCRIPTION
The oil temperature sensor is located on the right
side of the engine block. The sensor screws into the
engines main oil gallery (Fig. 74).
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Disconnect oil temperature sensor electrical
connector (Fig. 74).
(4) Remove oil temperature sensor from engine
block.
INSTALLATION
(1) Apply MopartThread Sealant to the sensor
threads.
(2) Install oil temperature sensor in engine block.
(3) Connect oil temperature sensor electrical con-
nector (Fig. 74)
Fig. 73 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
9a - 48 ENGINERG
OIL PUMP (Continued)
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(4) Lower vehicle.
(5) Start engine and check for leaks.
(6) Check and adjust oil level as necessary.
OIL PRESSURE RELIEF VALVE
DESCRIPTION
The oil pressure relief valve mounts in the front of
the engine block and is used to control oil flow
through the engines lubrication system (Fig. 75).
REMOVAL
(1) Remove engine oil pan (Refer to 9 - ENGINE/
LUBRICATION/OIL PAN - REMOVAL).
(2) Using special tool VM.1054, remove oil pres-
sure relief valve from engine block (Fig. 76).
INSTALLATION
(1) Thoroughly clean all components and relief
valve pocket in cylinder block.
(2) Lubricate all oil pressure relief valve compo-
nents with engine oil.
(3) Install oil pressure relief valve plunger, spring,
and cap.
Fig. 74 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
Fig. 75 OIL PRESSURE RELIEF VALVE
1 - O-RING
2 - OIL PRESSURE RELIEF VALVE CAP
3 - OIL PRESSURE RELIEF VALVE SPRING
4 - OIL PRESSURE RELIEF VALVE PLUNGER
Fig. 76 OIL PRESSURE RELIEF VALVE REMOVAL
1 - VM.1054
2 - OIL PRESSURE RELIEF VALVE
3 - ENGINE BLOCK
4 - OIL PUMP
RGENGINE9a-49
OIL TEMPERATURE SENSOR (Continued)
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(2) Install oil cooler, retaining bolt, and stud (Fig.
79). Torque retaining bolt to 47.1N´m and stud to
50N´m.
(3) Connect coolant hoses at cooler (Fig. 79).
(4) Install oil filter housing and retaining nut (Fig.
78). Torque retaining nut to 3.5 Kg.
(5) Install oil filter cartridge and oil filter cap
(Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -
INSTALLATION).
(6) Lower vehicle.
(7) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(8) Start engine and check for leaks.
(9) Check and adjust oil level as necessary.
OIL FILTER
DESCRIPTION
The oil filter used on this engine is a cartridge
style filter (Fig. 80).
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove oil filter cap drain plug and drain oil
from oil filter housing (Fig. 81).
(3) Remove oil filter cap with suitable oil filter
wrench (Fig. 81).
(4) Remove oil filter cartridge from housing.
INSTALLATION
(1) Clean oil filter cap and drain plug with suit-
able solvent.
(2) Install new oil filter cartridge in oil filter hous-
ing.
(3) Install oil filter cap and drain plug
(4) Lower vehicle from hoist.
(5) Start engine and check for leaks.
(6) Check and adjust oil level as necessary.
Fig. 80 OIL FILTER ASSEMBLY
1 - OIL FILTER CAP
2 - DRAIN PLUG
3 - OIL FILTER CARTRIDGE
Fig. 81 OIL COOLER AND FILTER ASSEMBLY
1 - WATER PUMP HOUSING
2 - OIL FILTER HOUSING
3 - OIL FILTER CAP
4 - OIL FILTER CAP DRAIN PLUG
5 - OIL COOLER
RGENGINE9a-51
OIL COOLER & LINES (Continued)
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ADJUSTMENTS
ADJUSTMENT - TIMING BELT TENSIONER
(1) With timing belt outer cover removed and tim-
ing belt installed.
(2) Loosen timing belt tensioner (Fig. 97).
(3) Align timing belt tensioner spring stop with
tensioner as shown (Fig. 98) and torque timing belt
tensioner retaining bolt to 34.7N´m.
(4) Rotate engine 2 complete revolution and then
recheck tensioner alignment. Readjust tensioner
alignment as necessary.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
CAUTION: Before removing the timing belt, the
engine must put at 90É after TDC. Failure to do so
could result in valve and/or piston damage during
reassembly. (Refer to 9 - ENGINE/VALVE TIMING -
STANDARD PROCEDURE)
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing assembly.
(4) Support engine and remove right engine
mount.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
Fig. 97 TIMING BELT TENSIONER ADJUSTMENT
1 - TIMING BELT IDLER PULLEY
2 - ENGINE FRONT COVER
3 - CRANKSHAFT HUB
4 - TIMING BELT TENSIONER
5 - TIMING BELT
Fig. 98 TIMING BELT TENSIONER ALIGNMENT
1 - TENSIONER SPRING STOP
2 - TIMING BELT TENSIONER
3 - TIMING BELT TENSIONER
4 - TIMING BELT
5 - TIMING BELT INNER COVER
9a - 60 ENGINERG
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EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXCESSIVE
EXHAUST SYSTEM NOISE...............2
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM RESTRICTION CHECK...........2
INSPECTION...........................3
ADJUSTMENTS.........................3
SPECIFICATIONS
TORQUE.............................3
SPECIAL TOOLS
EXHAUST SYSTEM.....................4
CATALYTIC CONVERTER
DESCRIPTION..........................4
OPERATION............................4REMOVAL.............................5
INSPECTION...........................6
INSTALLATION..........................6
CROSS-OVER PIPE - 3.3/3.8L
REMOVAL.............................6
INSTALLATION..........................6
HEAT SHIELDS
DESCRIPTION..........................6
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................7
MUFFLER
REMOVAL.............................7
INSTALLATION..........................8
RESONATOR
REMOVAL.............................9
INSTALLATION..........................9
EXHAUST SYSTEM
DESCRIPTION
The exhaust system consists of a catalytic converter,
muffler, and a resonator with connecting pipes in-be-
tween (Fig. 1). The system is serviced in two sections;
the catalytic converter and pipe, and the muffler and
resonator with connecting pipe. A band clamp is usedto connect the joint between the two components.
Three support hanger rods with rubber isolators are
used to support and isolate the exhaust system. A flex-
ible joint, integral to the catalytic converter, allows for
engine movement. On vehicles equipped with AWD, an
additional heat shield is mounted to the catalytic con-
verter. The exhaust system is tuned for each vehicle/
powertrain combination.
Fig. 1 Exhaust System - Typical (All Vehicles)
1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
RSEXHAUST SYSTEM11-1
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