DODGE TOWN AND COUNTRY 2001 Service Manual

- 124 kPa (14 - 18 psi). This air is replaced with cool-
ant from the coolant bottle.
NOTE: Deaeration does not occur at engine idleÐ
higher engine speeds are required. Normal driving
will deaerate cooling system.
To effectively deaerate the system, multiple ther-
mal cycles of the system may be required.
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE CAP, CYLINDER BLOCK
DRAIN PLUGS, OR THE DRAINCOCK WHEN THE
SYSTEM IS HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
(1)Without removing radiator pressure cap
and with system not under pressure, open the
draincock. The draincock is located on the lower left
side of radiator (Fig. 5).
(2) After the coolant recovery/reserve container is
empty, then remove coolant pressure cap (Fig. 6).
(3) Remove the cylinder block drain plug(s).
STANDARD PROCEDURE - COOLING SYSTEM
FILLING
Remove radiator pressure cap (Fig. 6) and fill sys-
tem, using a 50/50 mix of MopartAntifreeze/Coolant,
5 Year/100,000 Mile Formula and distilled water.
Continue filling system until full.Be careful not
to spill coolant on drive belts or the generator.
Fill coolant recovery/reserve container (Fig. 6) to at
least the MAX mark with 50/50 solution. It may be
necessary to add coolant to the recovery/reserve con-
tainer after three or four warm up/cool down cycles
to maintain coolant level between the MAX and MIN
mark. This will allow trapped air to be removed from
the system.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The radiator cap should not be removed.
When additional coolant is needed to maintain this
level, it should be added to the coolant recovery/re-
serve container (Fig. 6). Use only 50/50 mix of ethyl-
ene glycol type antifreeze and distilled water. For the
recommeded antifreeze/coolant type (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
Fig. 5 Draincock Location
1 - LEFT SIDE FRAME RAIL
2 - DRAINCOCK
7 - 4 COOLINGRS
COOLING (Continued)
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STANDARD PROCEDURE - COOLANT LEVEL
CHECK
NOTE: Do not remove radiator cap for routine cool-
ant level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without
removing the radiator cap.With the engine cold
and not running,simply observe the level of the
coolant in the recovery/reserve container (Fig. 7). The
coolant level should be between the MIN and MAX
marks.
Fig. 6 Cooling System Service Locations
1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL LEVEL DIPSTICK
2 - ENGINE OIL FILL CAP 4 - RADIATOR PRESSURE CAP
Fig. 7 Coolant Recovery Container
RSCOOLING7-5
COOLING (Continued)
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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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ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE
SPECIFICATIONS.........................7
BELT TENSIONER - 2.4L
REMOVAL...............................7
INSTALLATION............................7
BELT TENSIONER - 3.3/3.8L
REMOVAL...............................8
INSTALLATION............................8
DRIVE BELTS
DESCRIPTION............................8
OPERATION.............................8
DIAGNOSIS AND TESTING..................8ACCESSORY DRIVE BELT.................8
DRIVE BELTS - 2.4L
REMOVAL...............................9
CLEANING..............................10
INSPECTION............................10
INSTALLATION...........................10
ADJUSTMENTS..........................10
DRIVE BELTS - 3.3/3.8L
REMOVAL..............................11
CLEANING..............................11
INSPECTION............................11
INSTALLATION...........................12
ACCESSORY DRIVE
SPECIFICATIONS
SPECIFICATIONS - ACCESSORY BELT TENSION
ACCESSORY DRIVE
BELTGAUGE
2.4L ENGINE
A/C Compressor/
GeneratorDynamic Tensioner
Power SteeringNew Belt: 616 N (140
lbs.)
Used Belt: 396 N (90
lbs.)
3.3/3.8L ENGINES
A/C Compressor
Dynamic Tensioner
Generator/Water
Pump/Power Steering
BELT TENSIONER - 2.4L
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield.(3) Remove the generator/A/C drive belt. (Refer to
7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(4) Remove the belt tensioner (Fig. 1).
INSTALLATION
(1) Install belt tensioner and bolt (Fig. 1). Tighten
bolt to 28 N´m (250 in. lbs.).
(2) Install generator/A/C compressor drive belt.
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION)
(3) Install splash shield.
(4) Lower the vehicle.
Fig. 1 Belt Tensioner - 2.4L
1 - BELT TENSIONER
2 - BOLT
RSACCESSORY DRIVE7-7
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BELT TENSIONER - 3.3/3.8L
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield.
(3) Remove the drive belt. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)
(4) Remove the belt tensioner (Fig. 2).
INSTALLATION
(1) Install the belt tensioner and bolt (Fig. 2).
Tighten bolt to 28 N´m (250 in. lbs.).
(2) Install the drive belt. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION)
(3) Install the drive belt shield.
(4) Lower the vehicle.
DRIVE BELTS
DESCRIPTION
The drive belts are a Poly-V type belt. Belt widths
vary depending on the various engine and accessory
packages. Satisfactory performance of these belts
depends on belt condition and proper belt tension.
OPERATION
The accessory drive belts form the link between
the engine crankshaft and the engine driven accesso-
ries.
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
CONDITION POSSIBLE CAUSES CORRECTIONS
INSUFFICIENT ACCESSORY
OUTPUT DUE TO BELT SLIPPAGE1. Belt too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Belt excessively glazed or worn 2. Replace and tighten as specified
BELT SQUEAL WHEN
ACCELERATING ENGINE1. Belts too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Belt glazed 2. Replace belts
BELT SQUEAK AT IDLE 1. Belts too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Dirt or paint imbedded in belt 2. Replace belt
3. Non-uniform belt 3. Replace belt
4. Misaligned pulleys 4. Align accessories
5. Non-uniform groove or eccentric
pulley5. Replace pulley
Fig. 2 BELT TENSIONER - 3.3/3.8L
1 - BELT TENSIONER
2 - BOLT
7 - 8 ACCESSORY DRIVERS
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CONDITION POSSIBLE CAUSES CORRECTIONS
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. (a) Replace belt (auto-tensioned
belts.)
(b) Adjust power steering belt
tension (4 cyl. engine)
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric
pulley4. Replace pulley
DRIVE BELTS - 2.4L
REMOVAL
GENERATOR AND AIR CONDITIONING BELT
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield (Fig. 7).
WARNING: DO NOT ALLOW DRIVE BELT TEN-
SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
(3) Position a wrench on the belt tensioner lug
(Fig. 3).
(4) Release belt tension by rotating the tensioner
clockwise (Fig. 3).
(5) Remove belt.
(1) Carefully return tensioner to its relaxed posi-
tion.
POWER STEERING PUMP
(1) From top of the vehicle, loosen locking nuts (D)
and (F) (Fig. 4).
(2) From under the vehicle, loosen the pivot bolt
(E). Loosen adjusting bolt (G) until belt can be
removed.
Fig. 3 A/C & GENERATOR BELT TENSION RELEASE
1 - BELT TENSIONER
2 - WRENCH
Fig. 4 Power Steering Pump
1 - REAR LOCKING NUT (D)
2 - ADJUSTING BOLT (G)
3 - PIVOT BOLT (E)
4 - FRONT LOCKING NUT (F)
RSACCESSORY DRIVE7-9
DRIVE BELTS (Continued)
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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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DRIVE BELTS - 3.3/3.8L
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield (Fig. 7).
WARNING: DO NOT ALLOW DRIVE BELT TEN-
SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
(3) Position a wrench on the belt tensioner lug
(Fig. 8).
(4) Release belt tension by rotating the tensioner
counterclockwise (Fig. 8).(5) Remove the drive belt (Fig. 10).
(6) Carefully return tensioner to its relaxed posi-
tion.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. 9).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
Fig. 7 Accessory Drive Belt Shield
1 - ATTACHING SCREW
2 - ATTACHING SCREWS
3 - SPLASH SHIELD
Fig. 8 DRIVE BELT TENSION RELEASE
1 - BLET TENSIONER LUG
2 - WRENCH
Fig. 9 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
RSACCESSORY DRIVE7-11
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INSTALLATION
(1) Route and position the drive belt onto all pul-
leys, except for the crankshaft (Fig. 10).(2) Rotate belt tensioner counterclockwise until
belt can be installed onto the crankshaft pulley (Fig.
8). Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys.
(4) Install drive belt shield (Fig. 7) and lower vehi-
cle.
Fig. 10 ACCESSORY DRIVE BELT
1 - DRIVE BELT
2 - POWER STEERING PUMP PULLEY
3 - BELT TENIONER PULLEY
4 - IDLER PULLEY
5 - GENERATOR PULLEY
6 - AIR CONDITIONING COMPRESSOR PULLEY
7 - CRANKSHAFT PULLEY
8 - WATER PUMP PULLEY
7 - 12 ACCESSORY DRIVERS
DRIVE BELTS - 3.3/3.8L (Continued)
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ENGINE
TABLE OF CONTENTS
page page
ENGINE
DIAGNOSIS AND TESTING.................14
COOLING SYSTEM DIAGNOSIS...........14
CLEANING..............................17
INSPECTION............................17
COOLANT
DIAGNOSIS AND TESTING.................17
COOLANT CONCENTRATION TESTING......17
STANDARD PROCEDURE..................18
COOLANT SERVICE.....................18
COOLANT RECOVERY CONTAINER
DESCRIPTION...........................18
OPERATION.............................18
DIAGNOSIS AND TESTING.................19
COOLANT RECOVERY SYSTEM CHECK.....19
REMOVAL..............................19
INSTALLATION...........................19
ENGINE BLOCK HEATER
DESCRIPTION...........................19
OPERATION.............................19
DIAGNOSIS AND TESTING.................19
ENGINE BLOCK HEATER TESTING.........19
REMOVAL..............................19
INSTALLATION...........................19
ENGINE COOLANT TEMP SENSOR - 2.4L
DESCRIPTION...........................20
REMOVAL..............................20
INSTALLATION...........................20
ENGINE COOLANT TEMP SENSOR - 3.3/3.8L
DESCRIPTION...........................20
REMOVAL..............................20
INSTALLATION...........................21
ENGINE COOLANT THERMOSTAT
DESCRIPTION...........................21
OPERATION.............................21
DIAGNOSIS AND TESTING.................22
THERMOSTAT.........................22
ENGINE COOLANT THERMOSTAT - 2.4L
REMOVAL..............................22
INSTALLATION...........................22
ENGINE COOLANT THERMOSTAT - 3.3/3.8L
REMOVAL..............................23
INSTALLATION...........................23
RADIATOR
DESCRIPTION...........................24
OPERATION.............................24
REMOVAL..............................24INSTALLATION...........................25
RADIATOR DRAINCOCK
REMOVAL..............................25
INSTALLATION...........................25
RADIATOR PRESSURE CAP
DESCRIPTION...........................26
OPERATION.............................26
DIAGNOSIS AND TESTING.................26
COOLING SYSTEM PRESSURE CAP
TESTING.............................26
RADIATOR CAP TO FILLER NECK SEAL.....26
CLEANING..............................27
INSPECTION............................27
RADIATOR FAN
DESCRIPTION...........................27
OPERATION.............................28
DIAGNOSIS AND TESTING.................28
RADIATOR FAN MOTOR TEST.............28
REMOVAL..............................29
INSTALLATION...........................29
RADIATOR FAN RELAY
DESCRIPTION...........................29
OPERATION.............................29
REMOVAL..............................29
INSTALLATION...........................29
WATER PUMP - 2.4L
DESCRIPTION...........................30
OPERATION.............................30
REMOVAL..............................30
CLEANING..............................31
INSPECTION............................31
INSTALLATION...........................31
WATER PUMP - 3.3/3.8L
DESCRIPTION...........................32
OPERATION.............................32
REMOVAL..............................32
CLEANING..............................33
INSPECTION............................33
INSTALLATION...........................33
WATER PUMP INLET TUBE - 2.4L
DESCRIPTION...........................34
REMOVAL..............................34
INSTALLATION...........................34
WATER PUMP INLET TUBE - 3.3/3.8L
REMOVAL..............................35
INSTALLATION...........................35
RSENGINE7-13
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