DODGE TOWN AND COUNTRY 2001 Service Manual

(5) Remove the pull pin or Allen wrench from the
belt tensioner.
(6) Once the timing belt has been installed and
tensioner released, rotate the crankshaft two (2) com-
plete revolutions. Verify that the TDC marks on
crankshaft and timing marks on the camshafts are
aligned as shown in (Fig. 123).
(7) Install engine mount bracket to engine (Fig.
116).
(8) Install timing belt front covers and bolts.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION)
(9) Install air conditioning/generator belt tensioner
and pulley. (Refer to 7 - COOLING/ACCESSORY
DRIVE/BELT TENSIONERS - INSTALLATION)
(10) Install right engine mount. (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION)(11) Install crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION)
(12) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(13) Install drive belt splash shield.
(14) Install right front wheel.
(15) Connect make-up air hose to cylinder head
cover.
(16) Install air cleaner housing, upper cover, and
clean air tube.
TIMING BELT TENSIONER &
PULLEY
REMOVAL
(1) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(2) Remove timing belt idler pulley.
(3) Hold camshaft sprocket with Special Tool 6847
while removing bolt (Fig. 124). Remove both cam
sprockets.
Fig. 122 Timing Belt - Installation
1 - ROTATE CAMSHAFT SPROCKET TO TAKE UP BELT SLACK
2 - CAMSHAFT TIMING MARKS 1/2 NOTCH LOCATION
3 - CRANKSHAFT AT TDC
4 - INSTALL BELT IN THIS DIRECTION
Fig. 123 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
9 - 64 ENGINE 2.4LRS
TIMING BELT AND SPROCKET(S) (Continued)
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(4) Remove rear timing belt cover fasteners and
remove cover from engine (Fig. 125).
(5) Remove lower bolt attaching timing belt ten-
sioner assembly to engine and remove tensioneras
an assembly(Fig. 126).
INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting boltbut do not tighten
(Fig. 126). To properly align tensioner assemblyÐin-
stall one of the engine bracket mounting bolts (M10)
5 to 7 turns into the tensioner's upper mounting loca-
tion (Fig. 126).
(2) Torque the tensioner's lower mounting bolt to
61 N´m (45 ft. lbs.). Remove the upper bolt used for
tensioner alignment.
(3) Install rear timing belt cover and fasteners.
(4) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).
(5) Install camshaft sprockets. Use Special Tool
6847 to hold sprockets (Fig. 124), torque bolts to 101
N´m (75 ft. lbs.).
(6) Install the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
Fig. 124 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 125 Rear Timing Belt Cover Fasteners
1 - BOLTS - REAR COVER 7 N´m (60 in. lbs.)
2 - BOLTS - REAR COVER 28 N´m (250 in .lbs.)
3 - TIMING BELT TENSIONER
Fig. 126 Timing Belt Tensioner AssemblyÐRemoval/
Installation
1 - TIMING BELT TENSIONER ASSEMBLY
2 - TENSIONER ASSEMBLY UPPER BOLT
3 - TENSIONER ASSEMBLY LOWER BOLT
RSENGINE 2.4L9-65
TIMING BELT TENSIONER & PULLEY (Continued)
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BALANCE SHAFT
DESCRIPTION
The 2.4L engine is equipped with two nodular cast
iron balance shafts installed in a cast aluminum car-
rier attached to the lower cylinder block (Fig. 127).
OPERATION
The balance shafts are driven by the crankshaft
via a roller chain and sprockets. The balance shafts
are connected by helical gears. The dual counter
rotating shafts decrease second order vertical shak-
ing forces caused by component movement.
REMOVAL
BALANCE SHAFTS
(1) Drain engine oil.
(2) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(3) Remove chain cover, guide and tensioner (Fig.
128). Also see Carrier Assembly Removal for serviceprocedures requiring only temporary relocation of
assembly.
(4) Remove gear cover retaining stud (double
ended to also retain chain guide). Remove cover and
balance shaft gears (Fig. 128).
(5) Remove balance shaft gear, chain sprocket
retaining screws, and crankshaft chain sprocket.
Remove chain and sprocket assembly (Fig. 129).
Using two wide pry bars, work the sprocket back and
forth until it is off the shaft.
(6) Remove carrier gear cover and balance shafts
(Fig. 130).
(7) Remove four carrier to crankcase attaching
bolts to separate carrier from engine bedplate.
BALANCE SHAFT CARRIER
The following components will remain intact dur-
ing carrier removal. Gear cover, gears, balance shafts
and the rear cover (Fig. 131).
(1) Remove chain cover and driven balance shaft
chain sprocket screw.
(2) Loosen tensioner pivot and adjusting screws,
move driven balance shaft inboard through driven
Fig. 127 Balance Shafts and Carrier Assembly
1 - SPROCKET 7 - GEARS
2 - TENSIONER 8 - GEAR COVER
3 - PLUG 9 - CHAIN COVER
4 - CARRIER 10 - SPROCKET
5 - REAR COVER 11 - GUIDE
6 - BALANCE SHAFTS 12 - CHAIN
9 - 66 ENGINE 2.4LRS
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chain sprocket. Sprocket will hang in lower chain
loop.
(3) Remove carrier to crankcase attaching bolts to
remove carrier.
BALANCE SHAFT TIMING
BALANCE SHAFT INSTALLATION
Balance shaft and carrier assembly installation is
the reverse of the removal procedure.During instal-
lation crankshaft-to-balance shaft timing must
be established. Refer to Timing procedure in
this section.
(1) With balance shafts installed in carrier (Fig.
131) position carrier on crankcase and install four
attaching bolts and tighten to 54 N´m (40 ft. lbs.).
(2) Turn balance shafts until both shaft key ways
are up, parallel to vertical centerline of engine.
Install short hub drive gear on sprocket driven shaft
and long hub gear on gear driven shaft. After instal-
lation gear and balance shaft keyways must be up
with gear timing marks meshed as shown in (Fig.
132).
Fig. 128 Chain Cover, Guide and Tensioner
1 - STUD
2 - TENSIONER (ADJUSTER)
3 - GEAR COVER
4 - ADJUST SCREW
5 - PIVOT SCREW
6 - CHAIN COVER (CUTAWAY)
7 - GUIDE
Fig. 129 Drive Chain and Sprockets
1 - NICKEL PLATED LINK AND MARK
2 - GEAR/SPROCKET SCREWS
3 - NICKEL PLATED LINK AND DOT
Fig. 130 Gear Cover and Gears
1 - STUD (DOUBLE ENDED)
2 - DRIVE GEAR
3 - DRIVEN GEAR
4 - CARRIER DOWEL
5 - GEAR(S)
6 - GEAR COVER
RSENGINE 2.4L9-67
BALANCE SHAFT (Continued)
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(3) Install gear cover and tighten double ended
stud/washer fastener to 12 N´m (105 in. lbs.).
(4) Align flat on balance shaft drive sprocket to the
flat on crankshaft (Fig. 133).
(5) Install balance shaft drive sprocket on crank-
shaft using Special Tool 6052 (Fig. 134).
(6) Turn crankshaft until number 1 cylinder is at
top dead center (TDC). The timing marks on the
chain sprocket should line up with the parting line
on the left side of number one main bearing cap.
(Fig. 135).(7) Place chain over crankshaft sprocket so that
the plated link of the chain is over the number 1 cyl-
inder timing mark on the balance shaft crankshaft
sprocket (Fig. 135).
(8) Place balance shaft sprocket into the timing
chain (Fig. 135) and align the timing mark on the
sprocket (dot) with the (lower) plated link on the
chain.
Fig. 131 Balance Shaft - Removal/Installation
1 - REAR COVER
2 - CARRIER
3 - BALANCE SHAFT
Fig. 132 Gear Timing
1 - KEY WAYS UP
2 - GEAR ALIGNMENT DOTS
Fig. 133 Balance Shaft Sprocket Alignment to
Crankshaft
1 - ALIGN FLATS
Fig. 134 Balance Shaft Drive
1 - SPROCKET
2 - SPECIAL TOOL 6052
9 - 68 ENGINE 2.4LRS
BALANCE SHAFT (Continued)
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NOTE: The lower plated link is 8 links from the
upper link.
(9) With balance shaft keyways pointing up (12
o'clock) slide the balance shaft sprocket onto the nose
of the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.
NOTE: THE TIMING MARK ON THE SPROCKET, THE
(LOWER) NICKEL PLATED LINK, AND THE ARROW
ON THE SIDE OF THE GEAR COVER SHOULD LINE
UP WHEN THE BALANCE SHAFTS ARE TIMED
CORRECTLY.(10) If the sprockets are timed correctly, install the
balance shaft bolts and tighten to 28 N´m (250 in.
lbs.). A wood block placed between crankcase and
crankshaft counterbalance will prevent crankshaft
and gear rotation.
(11)CHAIN TENSIONING:
(a) Install chain tensioner loosely assembled.
(b) Position guide on double ended stud making
sure tab on the guide fits into slot on the gear
cover. Install and tighten nut/washer assembly to
12 N´m (105 in. lbs.).
(c) Place a shim 1 mm (0.039 in.) thick x 70 mm
(2.75 in.) long or between tensioner and chain.
Push tensioner and shim up against the chain.
Apply firm pressure 2.5±3 Kg (5.5±6.6 lbs.)
directly behind the adjustment slot to take up
all slack.Chain must have shoe radius contact as
shown in (Fig. 136).
(d) With the load applied, tighten top tensioner
bolt first, then bottom pivot bolt. Tighten bolts to
12 N´m (105 in. lbs.). Remove shim.
(e) Install carrier covers and tighten screws to
12 N´m (105 in. lbs.).
(12) Install pick-up tube and oil pan.
(13) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 135 Balance Shaft Timing
1 - MARK ON SPROCKET
2 - KEYWAYS UP
3 - ALIGN MARKS
4 - PLATED LINK
5 - PARTING LINE (BEDPLATE TO BLOCK)
6 - PLATED LINK
Fig. 136 Chain Tension Adjustment
1 - 1MM (0.039 IN.) SHIM
2 - TENSIONER (ADJUSTER) BOLT
3 - PIVOT BOLT
RSENGINE 2.4L9-69
BALANCE SHAFT (Continued)
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BALANCE SHAFT CARRIER
REMOVAL
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - REMOVAL)
INSTALLATION
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION)
BALANCE SHAFT CHAIN
REMOVAL
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - REMOVAL)
INSTALLATION
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION)
9 - 70 ENGINE 2.4LRS
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ENGINE 3.3/3.8L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L
DESCRIPTION...........................73
DIAGNOSIS AND TESTING.................74
ENGINE..............................74
ENGINE DIAGNOSIS - PERFORMANCE......74
ENGINE DIAGNOSIS - MECHANICAL........76
ENGINE OIL LEAK INSPECTION...........77
CYLINDER COMPRESSION PRESSURE
TEST................................78
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST........................79
STANDARD PROCEDURE..................79
MEASURING WITH PLASTIGAGE..........79
FORM-IN-PLACE GASKETS AND SEALERS. . . 79
ENGINE GASKET SURFACE PREPARATION . . 80
HYDROSTATIC LOCKED ENGINE..........81
REPAIR OF DAMAGED OR WORN
THREADS.............................81
ENGINE CORE AND OIL GALLERY PLUGS . . . 81
REMOVAL..............................82
INSTALLATION...........................84
SPECIFICATIONS........................86
SPECIAL TOOLS.........................90
AIR CLEANER ELEMENT
REMOVAL..............................93
INSTALLATION...........................93
AIR CLEANER HOUSING
REMOVAL..............................93
INSTALLATION...........................93
CYLINDER HEAD
DESCRIPTION...........................94
OPERATION.............................94
DIAGNOSIS AND TESTING.................94
CYLINDER HEAD GASKET...............94
REMOVAL..............................95
CLEANING..............................95
INSPECTION............................96
INSTALLATION...........................96
CYLINDER HEAD COVER(S)
DESCRIPTION...........................97
CYLINDER HEAD COVER - RIGHT
REMOVAL..............................97
INSTALLATION...........................98
CYLINDER HEAD COVER - LEFT
REMOVAL..............................98
INSTALLATION...........................99
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION...........................99
OPERATION.............................99STANDARD PROCEDURE..................99
VALVE SERVICE.......................99
REMOVAL.............................100
CLEANING.............................100
INSPECTION...........................100
INSTALLATION..........................101
VALVE SPRINGS
DESCRIPTION..........................101
OPERATION............................101
REMOVAL.............................101
INSPECTION...........................103
INSTALLATION..........................103
ROCKER ARMS
DESCRIPTION..........................103
OPERATION............................104
REMOVAL.............................104
DISASSEMBLY..........................105
ASSEMBLY............................105
INSTALLATION..........................105
VALVE STEM SEALS
DESCRIPTION..........................106
REMOVAL.............................106
INSTALLATION..........................106
ENGINE BLOCK
DESCRIPTION..........................106
STANDARD PROCEDURE.................106
CYLINDER BORE HONING...............106
CLEANING.............................107
INSPECTION...........................107
CAMSHAFT & BEARINGS (IN BLOCK)
DESCRIPTION..........................107
OPERATION............................107
REMOVAL.............................107
INSPECTION...........................108
INSTALLATION..........................108
CONNECTING ROD BEARINGS
STANDARD PROCEDURE.................109
CONNECTING ROD BEARING - FITTING....109
CRANKSHAFT
DESCRIPTION..........................109
OPERATION............................110
STANDARD PROCEDURE.................110
CRANKSHAFT END PLAY................110
REMOVAL.............................110
INSPECTION...........................111
INSTALLATION..........................111
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE.................113
CRANKSHAFT MAIN BEARING - FITTING . . . 113
RSENGINE 3.3/3.8L9-71
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REMOVAL.............................114
INSTALLATION..........................115
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................115
INSTALLATION..........................115
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................116
INSTALLATION..........................117
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL.............................117
INSTALLATION..........................117
FLEX PLATE
REMOVAL.............................118
INSTALLATION..........................118
HYDRAULIC LIFTERS (CAM IN BLOCK)
DESCRIPTION..........................118
DIAGNOSIS AND TESTING................118
HYDRAULIC LIFTERS...................118
REMOVAL.............................119
INSTALLATION..........................119
PISTON & CONNECTING ROD
DESCRIPTION..........................119
OPERATION............................120
STANDARD PROCEDURE.................120
CONNECTING ROD AND BEARING -
FITTING.............................120
PISTON - FITTING.....................121
REMOVAL.............................121
INSTALLATION..........................122
PISTON RINGS
STANDARD PROCEDURE.................124
PISTON RING - FITTING................124
REMOVAL.............................124
INSTALLATION..........................125
VIBRATION DAMPER
REMOVAL.............................126
INSTALLATION..........................126
ENGINE MOUNTING
DESCRIPTION..........................127
FRONT MOUNT
REMOVAL.............................127
INSTALLATION..........................127
LEFT MOUNT
REMOVAL.............................128
INSTALLATION..........................128
REAR MOUNT
REMOVAL.............................129
INSTALLATION..........................130
RIGHT MOUNT
REMOVAL.............................130
INSTALLATION..........................131
LUBRICATION
DESCRIPTION..........................131
OPERATION............................131
DIAGNOSIS AND TESTING................131
ENGINE OIL PRESSURE................131OIL
STANDARD PROCEDURE.................132
ENGINE OIL CHANGE..................132
ENGINE OIL LEVEL CHECK..............133
OIL COOLER & LINES
DESCRIPTION..........................134
OPERATION............................134
REMOVAL.............................134
INSTALLATION..........................134
OIL FILTER
REMOVAL.............................135
INSTALLATION..........................135
OIL FILTER ADAPTER
REMOVAL.............................135
INSTALLATION..........................135
OIL PAN
REMOVAL.............................136
CLEANING.............................136
INSPECTION...........................136
INSTALLATION..........................136
OIL PRESSURE RELIEF VALVE
REMOVAL.............................137
INSTALLATION..........................137
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION..........................137
OPERATION............................138
REMOVAL.............................138
INSTALLATION..........................138
OIL PUMP
DESCRIPTION..........................138
REMOVAL.............................138
DISASSEMBLY..........................138
CLEANING.............................138
INSPECTION...........................138
ASSEMBLY............................140
INSTALLATION..........................140
INTAKE MANIFOLD
DESCRIPTION..........................140
OPERATION............................141
DIAGNOSIS AND TESTING................141
INTAKE MANIFOLD LEAKS..............141
INTAKE MANIFOLD - UPPER 3.3L
STANDARD PROCEDURE.................141
MANIFOLD STRIPPED THREAD REPAIR....141
INTAKE MANIFOLD VACUUM PORT REPAIR . 142
REMOVAL.............................143
CLEANING.............................144
INSPECTION...........................144
INSTALLATION..........................144
INTAKE MANIFOLD - UPPER 3.8L
REMOVAL.............................145
CLEANING.............................146
INSPECTION...........................147
INSTALLATION..........................147
INTAKE MANIFOLD - LOWER
REMOVAL.............................148
CLEANING.............................148
9 - 72 ENGINE 3.3/3.8LRS
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INSPECTION...........................148
INSTALLATION..........................149
EXHAUST MANIFOLD
DESCRIPTION..........................150
OPERATION............................150
EXHAUST MANIFOLD - RIGHT
REMOVAL.............................150
CLEANING.............................151
INSPECTION...........................151
INSTALLATION..........................151
EXHAUST MANIFOLD - LEFT
REMOVAL.............................152
CLEANING.............................152INSPECTION...........................153
INSTALLATION..........................153
VALVE TIMING
STANDARD PROCEDURE.................153
VALVE TIMING VERIFICATION............153
TIMING CHAIN COVER
REMOVAL.............................153
INSTALLATION..........................154
TIMING CHAIN AND SPROCKETS
REMOVAL.............................156
INSPECTION...........................156
INSTALLATION..........................157
ENGINE 3.3/3.8L
DESCRIPTION
The 3.3 Liter (201 cu. in.) and 3.8 Liter (231 cu.
in.) engines are 60É V-6 engines with cast iron cylin-
der blocks and aluminum cylinder heads (Fig. 1). The
engine uses a single, block mounted camshaft with
pushrods to actuate the valves. These engines do not
have provisions for a free wheeling valve train.The firing order is 1±2±3±4±5±6. The cylinders are
numbered from the front of the engine to the rear.
The front cylinder bank is numbered 2, 4, and 6. The
rear cylinder bank is numbered 1, 3, and 5.
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 2).
Fig. 1 3.3/3.8L V-6 Engines
RSENGINE 3.3/3.8L9-73
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