torque DODGE TOWN AND COUNTRY 2001 Service Manual

SPECIFICATIONS
TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Accessory Drive Belt Tensioner
Assembly (3.3/3.8L)ÐBolt28 Ð 250
Generator & A/C Compressor Drive
Belt Tensioner Assembly (2.4L)Ð
Bolt28 Ð 250
Coolant Outlet Connector/
Thermostat Housing
(2.4 & 3.3/3.8L)ÐBolts 28 Ð 250
Water Pump
(2.4 & 3.3/3.8L)ÐBolts 12 Ð 105
Water Pump Inlet Tube (2.4L)Ð
Bolts12 Ð 105
Water Pump Inlet Tube (3.3/3.8L)Ð
Bolts28 Ð 250
Water Pump Pulley (3.3/3.8L)Ð
Bolts28 Ð 250
Radiator to A/C CondenserÐ
Screws5Ð45
Radiator FanÐScrews 5 Ð 45
Radiator Mounting (Upper
Bracket)ÐNuts8Ð70
SPECIAL TOOLS
COOLING SYSTEM
Cooling System Tester 7700
Coolant Refractometer 8286
Fig. 8 Belt Tension Gauge 7198
7 - 6 COOLINGRS
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CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
²Excessive wear
²Frayed cords
²Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 5).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
INSTALLATION
GENERATOR AND AIR CONDITIONING BELT
(1) Install belt onto all pulleys except for the
crankshaft (Fig. 6).
(2) Rotate belt tensioner clockwise until belt can
be installed onto the crankshaft pulley (Fig. 3).
Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys (Fig. 6).
(4) Install drive belt shield (Fig. 7) and lower vehi-
cle.
POWER STEERING PUMP
(1) Install belt over crankshaft and power steering
pump pulleys (Fig. 6).
(2) Apply an initial snug torque to fasteners (D),
(E), and (F) (Fig. 4).
(3) Tighten adjusting bolt (G) until the proper ten-
sion obtained (Fig. 4). Refer to Belt Tension Specifi-
cations (Refer to 7 - COOLING/ACCESSORY DRIVE
- SPECIFICATIONS).
(4) Tighten locking nuts (D) and (F) to 54 N´m (40
ft. lbs.) (Fig. 4).
(5) Tighten pivot bolt (E) to 54 N´m (40 ft. lbs.)
(Fig. 4).
ADJUSTMENTS
Satisfactory performance of the belt driven accesso-
ries depends on proper belt tension. Belt tensioning
should be performed with the aid of Special Tool
7198. Because of space limitations in the engine com-
partment, the use of this gauge may be restricted.
Raise the vehicle on a hoist and the remove the
splash shield to gain access to the drive belts, if nec-
essary. Adjust belt tension for either aNeworUsed
belt. For specifications, (Refer to 7 - COOLING/AC-
CESSORY DRIVE - SPECIFICATIONS).
Fig. 5 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
Fig. 6 Accessory Drive Belts - 2.4L
1 - POWER STEERING PUMP PULLEY
2 - BELT TENSIONER
3 - GENERATOR PULLEY
4 - BELT - A/C AND GENERATOR
5 - A/C COMPRESSOR PULLEY
6 - CRANKSHAFT PULLEY
7 - BELT - POWER STEERING
7 - 10 ACCESSORY DRIVERS
DRIVE BELTS - 2.4L (Continued)
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(13) Remove water pump attaching screws to
engine (Fig. 25).
CLEANING
Clean gasket mating surfaces as necessary.
INSPECTION
Replace water pump body assembly if it has any of
these defects:
(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by
wet coolant traces on the pump body.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the
engine block.
(5) Impeller loose or damaged.
(6) Sprocket or sprocket flange loose or damaged.
INSTALLATION
(1) Install new O-ring gasket in water pump body
O-ring groove (Fig. 26).
CAUTION: Make sure O-ring is properly seated in
water pump groove before tightening screws. Animproperly located O-ring may be damaged and
cause a coolant leak.
(2) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.) (Fig. 25). Pressurize
cooling system to 103.4 Kpa (15 psi) with pressure
tester and check water pump shaft seal and O-ring
for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install the timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(5) Install camshaft sprockets and torque bolts to
101 N´m (75 ft. lbs.).
(6) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).
(7) Install the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKET(S - INSTALLATION)
(8) Install the generator mount bracket. (Fig. 24)
(9) Install the generator.
(10) Install right engine mount bracket and engine
mount. (Refer to 9 - ENGINE/ENGINE MOUNTING/
RIGHT MOUNT - INSTALLATION)
Fig. 24 Generator Bracket
1 - BRACKET - ENGINE MOUNT 5 - BOLT
2 - BOLT 6 - TENSIONER - DRIVE BELT
3 - GENERATOR 7 - BOLT
4 - BOLT 8 - BOLT
RSENGINE7-31
WATER PUMP - 2.4L (Continued)
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SPECIFICATIONS
SPECIFICATIONS - TORQUE
2.5L DIESEL - TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Water Pump Housing Nuts 24.4 18 215
Thermostat Housing Bolts 27.5 21 Ð
Accessory Drive Belt
Tensioner Bolt47.1 35 Ð
Accessory Drive Belt Idler
Bolt53 39 Ð
SPECIFICATIONS - COOLING SYSTEM
CAPACITY
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Cooling System With
Auxiliary Heater16.6 Liters (17.5 qts.)
Cooling System With Out
Auxiliary Heater13.8 Liters (14.6 qts.)
7a - 8 COOLING 2.5L TURBO DIESELRG
COOLING 2.5L TURBO DIESEL (Continued)
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ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE
SPECIFICATIONS.........................9
BELT TENSIONER
REMOVAL...............................9
INSTALLATION............................9
IDLER PULLEY
REMOVAL..............................10
INSTALLATION...........................10DRIVE BELTS
DESCRIPTION...........................10
OPERATION.............................10
DIAGNOSIS AND TESTING.................11
ACCESSORY DRIVE BELT................11
REMOVAL..............................11
INSTALLATION...........................11
ACCESSORY DRIVE
SPECIFICATIONS
SPECIFICATIONS - ACCESSORY BELT TENSION
ACCESSORY DRIVE
BELTGAUGE
2.5L DIESEL ENGINE
A/C Compressor/
GeneratorDynamic Tensioner
Power Steering Belt 300 N (67 lbs.)
BELT TENSIONER
REMOVAL
WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE THE AUTO-
MATIC BELT TENSIONER. THE TENSIONER IS SER-
VICED AS AN ASSEMBLY.
(1) Remove the power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(3) Remove the belt tensioner retaining bolt and
remove tensioner (Fig. 1).
INSTALLATION
(1) Install belt tensioner and retaining bolt (Fig.
1). Torque bolt to 47 N´m (35ft. lbs.).(2) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(3) Install the power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
Fig. 1 BELT TENSIONER AND IDLER PULLEY
1 - BELT TENSIONER RETAINING BOLT
2 - BELT TENSIONER
3 - IDLER PULLEY
4 - VIBRATION DAMPER/CRANKSHAFT PULLEY
5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
BOLTS
RGACCESSORY DRIVE7a-9
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IDLER PULLEY
REMOVAL
(1) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
CAUTION: IDLER PULLEY RETAINING BOLT HAS
LEFT HAND THREAD
(2) Remove the idler pulley (Fig. 2).
INSTALLATION
(1) Install the idler pulley (Fig. 2). Torque retain-
ing bolt to 22 N´m (16 ft. lbs.).
(2) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(3) Install the power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
DRIVE BELTS
DESCRIPTION - ACCESSORY DRIVE BELT
The accessory drive belt is a serpentine type belt
(Fig. 3). Satisfactory performance of these belts
depends on belt condition and proper belt tension.
DESCRIPTION - POWER STEERING BELT
The power steering belt is a serpentine type belt
(Fig. 3). Satisfactory performance of this belt depends
on condition of the belt.
OPERATION-ACCESSORY DRIVE BELT
The accessory drive belts form the link between
the engine crankshaft and the engine driven accesso-
ries.
OPERATION-POWER STEERING BELT
The power steering belt forms a link between the
engine crankshaft and the power steering pump.
Fig. 2 BELT TENSIONER AND IDLER PULLEY
1 - BELT TENSIONER RETAINING BOLT
2 - BELT TENSIONER
3 - IDLER PULLEY
4 - VIBRATION DAMPER/CRANKSHAFT PULLEY
5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
BOLTS
Fig. 3 ACCESSORY DRIVE BELT ROUTING
1 - GENERATOR
2 - IDLER PULLEY
3 - A/C COMPRESSOR CLUTCH
4 - POWER STEERING PUMP PULLEY
5 - POWER STEERING BELT
6 - CRANKSHAFT DAMPER/PULLEY
7 - BELT TENSIONER
8 - ACCESSORY DRIVE BELT
7a - 10 ACCESSORY DRIVERG
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(4) Disconnect upper radiator hose adapter tube,
water pump hose, and EGR hose at thermostat hous-
ing.
(5) Remove both thermostat housing attaching
bolts and housing (Fig. 10).
INSTALLATION
(1) Install thermostat housing, gasket, and retain-
ing bolts (Fig. 10). Torque bolts to 27.5N´m.
(2) Connect upper radiator hose adapter tube,
water pump hose, and EGR cooler hose to thermostat
housing.
(3) Install front wiper unit (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Connect negative battery cable.
RADIATOR
DESCRIPTION
The radiator is a cross-flow type (horizontal tubes)
with design features that provide greater strength
along with sufficient heat transfer capabilities tokeep the engine satisfactorily cooled. The radiator
has plastic side tanks and aluminum cooling tubes.
OPERATION
The radiator functions as a heat exchanger, using
air flow across the exterior of the radiator tubes. This
heat is then transferred from the coolant and into
the passing air.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove radiator upper crossmember support.
(Refer to 23 - BODY/EXTERIOR/GRILLE OPENING
REINFORCEMENT - REMOVAL).
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(3) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE).
Fig. 9 THERMOSTAT HOUSING LOCATION
1 - CYLINDER HEAD COVER
2 - THERMOSTAT HOUSING
3 - AIR BLEED
4 - WATER PUMP
5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING
BYPASS HOSE
6 - E G R VA LV E
Fig. 10 THERMOSTAT HOUSING ASSEMBLY
1 - THERMOSTAT HOUSING GASKET
2 - THERMOSTAT HOUSING
3 - RETAINING BOLTS
4 - CYLINDER HEAD
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
7a - 20 ENGINERG
ENGINE COOLANT THERMOSTAT (Continued)
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REMOVAL - WATER PUMP HOUSING
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove both outer and inner timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(4) Disconnect water pump housing to thermostat
housing bypass hose (Fig. 16).
(5) Remove the water pump housing retaining
nuts (Fig. 17).
(6) Remove water pump housing from engine block
(Fig. 17).
CLEANING
Clean gasket mating surfaces as necessary.
INSTALLATION - WATER PUMP
(1) Clean gasket mating surfaces as necessary.
(2) Place water pump and gasket in place. Install
water pump retaining bolts (Fig. 15). Torque bolts to
24.4N´m.
(3) Install both inner and outer timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).(5) Connect negative battery cable.
INSTALLATION - WATER PUMP HOUSING
(1) Clean mating serfaces of water pump housing
and engine block as necessary.
(2) Place new o-ring in groove in water pump
housing (Fig. 18).
(3) Be sure lower radiator hose tube o-ring is in
place.
(4) Install water pump housing on lower radiator
hose tube and push on mounting studs (Fig. 17).
Torque retaining nuts to 24.4N´m.
(5) Connect water pump housing to thermostat
housing bypass hose (Fig. 16).
(6) Install both inner and outer timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION).
(7) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(8) Connect negative battery cable.
Fig. 15 WATER PUMP LOCATION
1 - CYLINDER HEAD
2 - ENGINE BLOCK
3 - OIL COOLER
4 - OIL FILTER HOUSING
5 - WATER PUMP
Fig. 16 THERMOSTAT HOUSING LOCATION
1 - CYLINDER HEAD COVER
2 - THERMOSTAT HOUSING
3 - AIR BLEED
4 - WATER PUMP
5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING
BYPASS HOSE
6 - E G R VA LV E
RGENGINE7a-23
WATER PUMP (Continued)
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²Front Fog Lamp Relay Actuation
²Front and Rear Blower Motor Relay Actuation
²Accessory Relay Actuation
²Electronic Back Light (EBL) Rear Defogger
²Horn Relay Actuation
²Park Lamp Relay Actuation
²Name Brand Speaker (NBS) Relay Actuation
²Headlamp Washer Relay Actuation
²Diesel Cabin Heater (Diesel Engine Vehicles)
The following inputs areReceived/Monitoredby
the Front Control Module:
²B+ Connection Detection
²Ambient Temperature Sensing
²Right/Left Park Lamp Outage
²Ignition Switch Start Only
²Ignition Switch Run and Start Only
²Washer Fluid Level
²Windshield Wiper Park
²Brake Fluid Level
²Back-Up switch
²Stop Lamp Sense
²Engine Crank Signal (Diesel Engine Vehicles)
²Horn Input
DIAGNOSIS AND TESTING - FRONT CONTROL
MODULE
The front control module is a printed circuit board
based module with a on-board micro-processor. The
front control module interfaces with other electronic
modules in the vehicle via the Programmable Com-
munications Interface (PCI) data bus (J1850). In
order to obtain conclusive testing the Programmable
Communications Interface (PCI) data bus network
and all of the electronic modules that provide inputs
to, or receive outputs from the front control module
must be checked. All PCI (J1850) communication
faults must be resolved prior to further diagnosing
any front control module related issues.
The front control module was designed to be diag-
nosed with an appropriate diagnostic scan tool, such
as the DRB IIIt. The most reliable, efficient, and
accurate means to diagnose the front control module
requires the use of a DRB IIItscan tool and the
proper Body Diagnostic Procedures manual.
Before any testing of the front control module is
attempted, the battery should be fully charged and
all wire harness and ground connections inspected
around the affected areas on the vehicle.
REMOVAL
(1) Disconnect the positive and negative battery
cables from the battery.
(2) Remove the battery from the vehicle. Refer to
the procedure in Battery Systems.(3) Using a long flat-pladed screwdriver, gently
twist the Intelligent Power Module (IPM) retaining
clip outboard to free the intelligent power module
from its mounting bracket (Fig. 6). Rotate intelligent
power module upward to access the Front Control
Module (FCM) retaining screws.
(4) Remove the front control module retaining
screws.
(5) Using both hands, pull the front control module
straight from the intelligent power module assembly
to disconnect the 49-way electrical connector (Fig. 7)
and remove the front control module from the vehi-
cle.
INSTALLATION
(1) Install the front control module in the intelli-
gent power module assembly by pushing the 49-way
electrical connector straight in (Fig. 7).
(2) Install the front control module retaining
screws. Torque the screws to 7 in. lbs.
(3) Rotate the intelligent power module assembly
downward to secure in mounting bracket.
(4) Install the battery in the vehicle. Refer to the
procedure in Battery Systems.
(5) Connect the positive and negative battery
cables.
NOTE: If the vehicle is not equipped with Name
Brand Speakers (NBS, Infinity) or Headlamp Wash-
ers the DRB IIITmust be used to Disable the appro-
priate relays in the Intelligent Power Module
Assembly.
Fig. 6 REMOVING INTELLIGENT POWER MODULE
8E - 6 ELECTRONIC CONTROL MODULESRS
FRONT CONTROL MODULE (Continued)
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INSTALLATION
(1) Install the PLG control module on the D-pillar
and install retaining screw. Torque the screw to 14.5
in. lbs.
(2) Connect the wire harness connections on the
PLG control module. Be certain to slide connector
locks to the locked position.
(3) Install the D-pillar trim panel on the vehicle.
Refer to the Body section for the procedure.
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check any
erase any PLG control module diagnostic trouble
codes.
(6) Verify PLG system operation. Cycle the PLG
through one complete open and close cycle, this will
allow the PLG control module to relearn its cycle
with the new components.
POWERTRAIN CONTROL
MODULE
DESCRIPTION
The Powertrain Control Module (PCM) is a digital
computer containing a microprocessor (Fig. 10). The
PCM receives input signals from various switchesand sensors referred to as Powertrain Control Mod-
ule Inputs. Based on these inputs, the PCM adjusts
various engine and vehicle operations through
devices referred to as Powertrain Control Module
Outputs.
NOTE: PCM Inputs:
²Air Conditioning Pressure Transducer
²ASD Relay
²Battery Voltage
²Brake Switch
²Camshaft Position Sensor
²Crankshaft Position Sensor
²Distance Sensor (from transmission control mod-
ule)
²EGR Position Feedback
²Engine Coolant Temperature Sensor
²Heated Oxygen Sensors
²Ignition sense
²Intake Air Temperature Sensor
²Knock Sensor
²Leak Detection Pump Feedback
²Manifold Absolute Pressure (MAP) Sensor
²Park/Neutral (from transmission control module)
²PCI Bus
²Power Steering Pressure Switch
²Proportional Purge Sense
²SCI Receive
²Speed Control
Fig. 9 LIFTGATE CONTROL MODULE
1 - POWER LIFTGATE CONTROL MODULE
2 - MODULE RETAINING SCREWS
3 - D-PILLAR
4 - POWER LIFTGATE MOTOR
5 - MODULE ELECTRICAL CONNECTORS
Fig. 10 Powertrain Control Module (PCM)
1 - Battery
2 - Power Distribution Center
3 - Powertrain Control Module
8E - 8 ELECTRONIC CONTROL MODULESRS
POWER LIFTGATE MODULE (Continued)
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