transmission removal CHRYSLER TOWN AND COUNTRY 2002 Workshop Manual

CRANKSHAFT OIL SEAL -
REAR
REMOVAL
This must be done with either the engine or trans-
mission removed from vehicle.
(1) Remove flywheel assembly.
(2) Pry out old crankshaft oil seal.
INSTALLATION
(1) Using special tool VM.1050, install rear crank-
shaft oil seal in rear main bearing support (Fig. 69).
(2) Install engine or tranmission in vehicle.
OIL PAN
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Drain engine oil from engine.
(4) Remove all oil pan retaining bolts and oil pan
(Fig. 70).
INSTALLATION
(1) Clean oil pan and sealing surfaces. Inspect oil
pan and engine block.
(2) Install oil pan, gasket, and retaining bolts (Fig.
70).
(3) Be sure power steering line brackets are in
proper location (Fig. 70).
(4) Torque oil pan bolts to 11.8N´m.
(5) Lower vehicle.
(6) Refill engine oil to proper level.
(7) Connect negative battery cable.
Fig. 69 REAR CRANKSHAFT OIL SEAL
INSTALLATION USING VM.1050
1 - SPECIAL TOOL VM.1050
2 - REAR MAIN BEARING SUPPORT
3 - OIL PAN
4 - ENGINE TO TRANSMISSION ADAPTER PLATE
Fig. 70 OIL PAN AND PRESSURE RELIEF VALVE
1 - OIL PAN RETAINING BOLTS
2 - POWER STEERING LINE BRACKETS
3 - OIL PAN GASKET
4 - OIL PRESSURE SENSOR
5 - ENGINE BLOCK
6 - OIL PRESSURE RELIEF VALVE
7 - OIL PAN RETAINING BOLTS
8 - OIL PAN
9a - 46 ENGINERG
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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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(1) Disconnect and remove the upstream (before
catalytic converter) oxygen sensor. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/O2 SENSOR -
REMOVAL)
(2) Install the Exhaust Back Pressure Fitting
Adaptor CH8519.
(3) Connect the Low Pressure Sensor (15 psi)
CH7063 to the back pressure fitting.
(4) Following the PEP module instruction manual,
connect all required cables to the DRB IIItand PEP
module. Select the available menu options on the
DRBIIItdisplay screen for using the digital pressure
gauge function.
(5) Apply the park brake and start the engine.
(6) With transmission in Park or Neutral, raise
engine speed to 2000 RPM. Monitor the pressure
readings on the DRBIIIt. Back pressure should not
exceed specified limit. Refer to specification in table
below EXHAUST BACK PRESSURE LIMITS .
NOTE: For applications with dual catalytic convert-
ers, repeat test on opposite converter using the
previous steps.
(7) If pressure exceeds maximum limits, inspect
exhaust system for restricted component. For further
catalytic converter inspection procedures, (Refer to 11
- EXHAUST SYSTEM/CATALYTIC CONVERTER -
INSPECTION). Replace component(s) as necessary.
EXHAUST BACK PRESSURE LIMITS
Exhaust Back Pressure Limit (Max)
Vehicle in Park/Neutral
(no load) RPM3.45 Kpa (0.5 psi)
INSPECTION
Inspect the exhaust pipes, catalytic converters,
muffler, and resonators for cracked joints, broken
welds and corrosion damage that would result in a
leaking exhaust system. Inspect the clamps, support
brackets, and insulators for cracks and corrosion
damage.
NOTE: Slip joint band clamps are spot welded to
exhaust system. If a band clamp must be replaced,
the spot weld must be ground off.
ADJUSTMENTS
A misaligned exhaust system is usually indicated
by a vibration, rattling noise, or binding of exhaust
system components. These noises are sometimes hard
to distinguish from other chassis noises. Inspect
exhaust system for broken, damaged or loose compo-
nents such as; clamps, heat shields, isolators, andhanger brackets. Replace or tighten as necessary. It
is important that exhaust system clearances and
alignment be maintained.
Perform the following procedures to align the
exhaust system:
(1) Loosen band clamp at catalytic converter pipe
to muffler/resonator assembly.
(2) Align the exhaust system by inserting pipe
inward or outward until specification is achieved as
shown in (Fig. 2).
(3) Tighten band clamp to 54 N´m (40 ft. lbs.).
SPECIFICATIONS
TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Band Clamp 54 40 Ð
Cross-over PipeÐFastener 41 30 Ð
Exhaust Manifold FlangeÐFastener 37 Ð 325
Heat Shield (Muffler)ÐFastener 2.6 Ð 23
Heat Shield (Toe Board)ÐFastener 2.6 Ð 23
Heat Shield (Resonator Pipe)Ð
Fastener2.6 Ð 23
Insulator Mounting BracketÐBolts 28 Ð 250
Fig. 2 Exhaust System Alignment
1 - HANGER BRACKET TO BODY
2 - ISOLATOR
3 - HANGER - MUFFLER/RESONATOR SUPPORT
4-6mm(0.25 in.)
RSEXHAUST SYSTEM11-3
EXHAUST SYSTEM (Continued)
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FUEL FILTER
REMOVAL
(1) Release fuel pressure, refer to the Fuel release
procedure in this section.
(2) Disconnect the negative battery cable.
(3) Raise vehicle and support.
(4) Support the fuel tank with a transmission jack.
(5) Remove fuel line from the front of the tank.
(6) Remove ground strap
(7) Remove the inboard side of the fuel tank straps
and front T strap fastner.
(8) Lower the tank about 6 inches (Fig. 1).
(9) Remove fuel lines from the fuel pump module.
(10) Remove fuel filter from tank.
INSTALLATION
(1) Install fuel filter to tank. Tighten bolt to 4.5
N´m (40 in. lbs.)
(2) Install fuel lines to the fuel pump module (Fig.
1).
(3) Raise tank into position.
(4) Install the fuel tank straps.Tighten bolt for
main straps to 54 N´m (40 ft. lbs.) and the T strap
bolt to 28.2 N´m (250 in. lbs.)
(5) Install the ground strap
(6) Connect the fuel line at the front of the tank.
(7) Lower vehicle.
(8) Connect the negative battery cable.
(9) Pressurize the fuel system with the DRBIIIt
and check for leaks.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge level sending unit is attached to the
side of fuel pump module. The level sensor is a vari-
able resistor.
OPERATION
Its resistance changes with the amount of fuel in
the tank. The float arm attached to the sensor moves
as the fuel level changes.
The fuel level input is used as an input for OBD II.
If the fuel level is below 15% or above 85% of total
tank capacity several monitors are disabled. There
are diagnostics for the level circuit open and shorted.
REMOVAL
Remove fuel pump module. Refer to Fuel Pump
Module in this section.
(1) Depress retaining tab and remove the fuel
pump/level sensor connector from theBOTTOMof
the fuel pump module electrical connector (Fig. 2) .
NOTE: The pump module harness on TOP of flange
is not serviceable or removable.
Fig. 1 FUEL FILTER
Fig. 2 Fuel Pump/Level Sensor Electrical Connector
1 - ELECTRICAL CONNECTOR
2 - RETAINING TAB
14 - 4 FUEL DELIVERYRS
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REMOVAL
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure (Fig. 15).
(2) Disconnect negative cable from battery.
(3) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(4) Drain fuel tank dry into holding tank or a
properly labeledGASOLINEsafety container.
(5) Raise vehicle on hoist and support.
(6) Use a transmission jack to support fuel tank.
Remove bolts from fuel tank straps.
(7) Lower tank slightly.
(8) Disconnect the fuel filler vent tube. Squeeze
tabs and pull apart (Fig. 16).
(9) Disconnect the fuel fill hose at the fuel tank
filler metal tubeNOT AT THE FUEL TANK(Fig.
16).
(10) Disconnect fuel line and vapor line at the
front of the fuel tank.
The fuel pump module electrical connector
has a retainer that locks it in place.
(11) Slide fuel pump module electrical connector
lock to unlock (Fig. 17).
(12) Push down on connector retainer (Fig. 18) and
pull connector off module.
(13) Lower tank from vehicle. Remove fuel filler
vent tube from frame (Fig. 19).
INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect rollover valve hose. Connect fuel filler tube vent
hose and tighten clamp.
(2) Raise tank into position and carefully work
filler metal tube into the rubber hose on fuel tank. A
light coating of clean engine oil on the tube end may
be used to aid assembly.
Fig. 15 Fuel Tank
1 - ROLLOVER VALVE
2 - FUEL FILLER INLET
3 - ROLLOVER VALVE
4 - GROUND STRAP
5 - FUEL FILTER
6 - FUEL PUMP MODULEFig. 16 FUEL FILLER AND VENT TUBE
1 - Filler Tube
2 - Vent Tube
Fig. 17 Fuel Line Retainers and Pump Connector
Lock
1 - PUSH
2 - CONNECTOR LOCK
3 - QUICK CONNECT RETAINERS
RSFUEL DELIVERY14-11
FUEL TANK (Continued)
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(3) Feed filler vent line thru frame rail. Careful
not to cross lines.
(4) Tighten strap bolts to 54 N´m (40 ft. lbs.)
torque. Tighten T strap bolt to 28.2 N´m (250 in.
lbs.). Remove transmission jack.
(5) Tighten filler hose clamp to 3.3 N´m (30 in.
lbs.).
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(6) Connect fuel pump/module electrical connector.
Place retainer in locked position.(7) Lubricate the fuel supply line with clean 30
weight engine oil, install the quick connect fuel fit-
ting. Refer to Tube/Fitting Assembly in the Fuel
Delivery section of this section.
(8) Attach filler vent line to filler tube. Pull on
connector to make sure of connection.
(9) Fill fuel tank, replace cap, and connect battery
negative cable.
(10) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
FUEL TANK FILLER TUBE
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the 3 screws at the filler door.
(3) Raise and support vehicle
(4) Remove the left rear tire.
(5) Remove the splash shield (Fig. 20).
(6) Remove the canister from filler tube (Fig. 21).
(7) Disconnect the vent at the top of the filler tube.
(8) Remove the ground strap.
(9) Remove filler tube at tank.
INSTALLATION
(1) Install filler tube to tank (Fig. 20).
(2) Install the ground strap.
(3) Connect the vent at the top of the filler tube.
Fig. 18 Pump Module Connector Retainer and Lock
1 - PUSH DOWN ON RETAINER
2 - CONNECTOR LOCK
Fig. 19 VENT HOSE
Fig. 20 FUEL FILLER TUBE AND VENT TUBE
14 - 12 FUEL DELIVERYRS
FUEL TANK (Continued)
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OPERATION
The crankshaft position sensor detects slots cut
into the transmission driveplate extension (Fig. 6).
There are 3 sets of slots. Each set contains 4 slots,
for a total of 12 slots (Fig. 7). Basic timing is set by
the position of the last slot in each group. Once the
Powertrain Control Module (PCM) senses the last
slot, it determines crankshaft position (which piston
will next be at TDC) from the camshaft position sen-
sor input. The 4 pulses generated by the crankshaft
position sensor represent the 69É, 49É, 29É, and 9É
BTDC marks. It may take the PCM one engine rev-
olution to determine crankshaft position.
The PCM uses crankshaft position reference to
determine injector sequence, ignition timing and the
presence of misfire. Once the PCM determines crank-
shaft position, it begins energizing the injectors in
sequence.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) Disconnect the electrical connector (Fig. 8).
(4) Remove crankshaft sensor bolt.
(5) Remove the crankshaft sensor.
INSTALLATION - 2.4L
(1) Install the crankshaft sensor.
(2) Install crankshaft sensor bolt and tighten.
(3) Connect the electrical connector (Fig. 8).(4) Lower vehicle.
(5) Connect the negative battery cable.
ENGINE SPEED SENSOR
DESCRIPTION
The PCM receives a signal from the TCM and the
transaxle output speed sensor over the bus communi-
cation line to indicate vehicle speed on automatic
transmission cars. On Manual transmission cars (if
equipped) vehicle, a dedicated vehicle speed sensor is
connected to the PCM.
Fig. 6 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
Fig. 7 Timing Slots
1 - TORQUE CONVERTER DRIVE PLATE
2 - SLOTS
Fig. 8 CRANKSHAFT SENSOR 2.4L
14 - 24 FUEL INJECTIONRS
CRANKSHAFT POSITION SENSOR (Continued)
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OPERATION
The Transmission Control Module (TCM) supplies
the road speed and distance traveled inputs to the
PCM. From these inputs and the throttle position
sensor input, the PCM determines when a decelera-
tion condition occurs.
FUEL INJECTOR
DESCRIPTION
The injectors are positioned in the intake manifold
or cylinder head with the nozzle ends directly above
the intake valve port (Fig. 9).
OPERATION
The fuel injectors are 12 volt electrical solenoids
(Fig. 10). The injector contains a pintle that closes off
an orifice at the nozzle end. When electric current is
supplied to the injector, the armature and needle
move a short distance against a spring, allowing fuel
to flow out the orifice. Because the fuel is under high
pressure, a fine spray is developed in the shape of a
hollow cone or two streams. The spraying action
atomizes the fuel, adding it to the air entering the
combustion chamber. Fuel injectors are not inter-
changeable between engines.
The PCM provides battery voltage to each injector
through the ASD relay. Injector operation is con-
trolled by a ground path provided for each injector by
the PCM. Injector on-time (pulse-width) is variable,
and is determined by the PCM processing all the
data previously discussed to obtain the optimum
injector pulse width for each operating condition. Thepulse width is controlled by the duration of the
ground path provided.
REMOVAL
REMOVAL - 2.4L
The fuel rail must be removed first (Fig. 11). Refer
to Fuel Rail Removal in this section.
(1) Disconnect injector wiring connector from injec-
tor.
(2) Position fuel rail assembly so that the fuel
injectors are easily accessible (Fig. 12).
(3) Rotate injector and pull injector out of fuel rail.
The clip will stay on the injector.
(4) Check injector O-ring for damage. If O-ring is
damaged, it must be replaced. If injector is reused, a
protective cap must be installed on the injector tip to
Fig. 9 Fuel Injector Location - Typical
1 - FUEL RAIL
2 - INTAKE MANIFOLD
3 - FUEL INJECTORS
Fig. 10 FUEL INJECTOR - TYPICAL
1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
Fig. 11 FUEL RAIL AND INJECTORS 2.4L
1 - Fuel Injectors
2 - Fuel Rail
RSFUEL INJECTION14-25
ENGINE SPEED SENSOR (Continued)
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²Manifold pressure
²Injector pulse-width
²Spark-advance programs
²Shift-point strategies (F4AC1 transmissions
only, via the PCI bus)
²Idle speed
²Decel fuel shutoff
The PCM recognizes a decrease in manifold pres-
sure by monitoring a decrease in voltage from the
reading stored in the barometric pressure memory
cell. The MAP sensor is a linear sensor; as pressure
changes, voltage changes proportionately. The range
of voltage output from the sensor is usually between
4.6 volts at sea level to as low as 0.3 volts at 26 in. of
Hg. Barometric pressure is the pressure exerted by
the atmosphere upon an object. At sea level on a
standard day, no storm, barometric pressure is 29.92
in Hg. For every 100 feet of altitude barometric pres-
sure drops .10 in. Hg. If a storm goes through it can
either add, high pressure, or decrease, low pressure,
from what should be present for that altitude. You
should make a habit of knowing what the average
pressure and corresponding barometric pressure is
for your area.
REMOVAL
REMOVAL - 2.4L
(1) Disconnect the negative battery cable.
(2) Disconnect electrical connector and vacuum
hose from MAP sensor (Fig. 18).
(3) Remove two screws holding sensor to the
intake manifold.
REMOVAL - 3.3/3.8L
(1) Disconnect the negative battery cable.
(2) Remove vacuum hose and mounting screws
from manifold absolute pressure (MAP) sensor (Fig.
19).
(3) Disconnect electrical connector from sensor.
Remove sensor.
INSTALLATION
INSTALLATION - 2.4L
(1) Install sensor.
(2) Install two screws and tighten.
(3) Connect the electrical connector and vacuum
hose to the MAP sensor (Fig. 18).
(4) Connect the negative battery cable.
INSTALLATION - 3.3/3.8L
(1) Install sensor (Fig. 19).(2) Install screws and tighten toPLASTIC MAN-
IFOLD 1.7 N´m (15 in. lbs.) ALUMINUM MANI-
FOLD 3.3 N´m (30 in. lbs.).
(3) Connect the electrical connector to the sensor.
Install vacuum hose.
(4) Connect the negative battery cable.
O2 SENSOR
DESCRIPTION
The upstream oxygen sensor threads into the out-
let flange of the exhaust manifold (Fig. 20) or (Fig.
21).
Fig. 20 O2 SENSOR UPSTREAM 1/1 - 2.4L
Fig. 21 O2 SENSOR UPSTREAM 1/1 - 3.3/3.8L
14 - 30 FUEL INJECTIONRS
MAP SENSOR (Continued)
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