power steering DODGE TOWN AND COUNTRY 2001 Owner's Manual

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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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 COOLANT TEMP
SENSOR - 2.4L
DESCRIPTION
The engine coolant temperature sensor threads
into the top of the thermostat housing (Fig. 3). New
sensors have sealant applied to the threads.
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Drain the cooling system below thermostat
level. (Refer to 7 - COOLING - STANDARD PROCE-
DURE)
(2) Disconnect coolant temperature sensor electri-
cal connector.
(3) Remove coolant temperature sensor (Fig. 3).
INSTALLATION
(1) Install coolant temperature sensor (Fig. 3).
Tighten sensor to 7 N´m (60 in. lbs.).
(2) Connect electrical connector to sensor.
(3) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
ENGINE COOLANT TEMP
SENSOR - 3.3/3.8L
DESCRIPTION
The engine coolant temperature sensor threads
into a coolant passage on lower intake manifold near
the thermostat (Fig. 6). New sensors have sealant
applied to the threads.
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Drain cooling system below engine coolant tem-
perature sensor level. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(2) Remove power steering reservoir and relocate
(Fig. 4). Do not disconnect hoses.
Fig. 3 Engine Coolant Temperature Sensor - 2.4L
1 - MAP SENSOR
2 - COOLANT TEMPERATURE SENSORFig. 4 Power Steering Fluid Reservoir
1 - POWER STEERING RESERVOIR
2 - BOLT - RESERVOIR TO MANIFOLD
3 - NUT - RESERVOIR TO COIL BRACKET
7 - 20 ENGINERS
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(3) Remove ignition coil and bracket (Fig. 5).
(4) Disconnect coolant sensor electrical connector
(Fig. 6).
(5) Remove coolant sensor (Fig. 6).
INSTALLATION
(1) Install engine coolant temperature sensor (Fig.
6). Tighten sensor to 7 N´m (60 in. lbs.).
(2) Connect electrical connector to sensor (Fig. 6).
(3) Install ignition coil bracket (Fig. 5).
(4) Install ignition coil (Fig. 5).
(5) Install power steering reservoir (Fig. 4).
(6) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
ENGINE COOLANT
THERMOSTAT
DESCRIPTION
The engine cooling thermostats are a wax pellet
driven, reverse poppet choke type. The thermostat is
mounted in a housing on the coolant outlet of the
engine (Fig. 8) or (Fig. 10).
OPERATION
The engine cooling thermostat is a wax pellet
driven, reverse poppet choke type. The thermostat is
designed to provide the fastest warm up possible by
preventing leakage through it and to guarantee a
minimum engine operating temperature of 88 to
93ÉC (192 to 199ÉF). The thermostat also will auto-
matically reach wide open so it will not restrict flow
to the radiator as temperature of the coolant rises in
hot weather to around 104ÉC (220ÉF). Above this
temperature the coolant temperature is controlled by
the radiator, fan, and ambient temperature, not the
thermostat.
The thermostat is operated by a wax filled con-
tainer (pellet) which is sealed. When heated coolant
reaches a predetermined temperature, the wax
expands enough to overcome the closing spring and
water pump pressure, which forces the valve to open.
Fig. 5 Fuel Rail, Ignition Coil and Bracket
1 - FUEL RAIL
2 - BOLT - FUEL RAIL
3 - NUT - IGNITION COIL
4 - BOLT - IGNITION COIL
5 - IGNITION COIL
6 - BRACKET - IGNITION COIL
7 - STUD - IGNITION COIL
8 - SEPARATOR - SPARK PLUG CABLE
9 - BRACKET - SPARK PLUG CABLE SEPARATOR
10 - BOLT - SEPARATOR BRACKET
11 - BRACKET - SPARK PLUG CABLE SEPARATOR
Fig. 6 Engine Coolant Temperature Sensor
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
RSENGINE7-21
ENGINE COOLANT TEMP SENSOR - 3.3/3.8L (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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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)
2. Faulty belt tensioner 2. Replace tensioner as necessary
3. Belt excessively glazed or worn 3. Replace belt
BELT SQUEAL WHEN
ACCELERATING ENGINE1. Belts too loose 1. Check and replace belt tensioner if
necessary
2. Belt glazed 2. Replace belt
BELT SQUEAK AT IDLE 1. Belts too loose 1. (a) Replace belt
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
BELT ROLLED OVER IN
GROOVE OR BELT JUMPS
OFF1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. Replace belt
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric
pulley4. Replace pulley
REMOVAL-ACCESSORY DRIVE BELT
(1) Remove the power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Relieve tension on belt tensioner using a suit-
able wrench (Fig. 4) and lock tensioner with a drift
punch (Fig. 5).
(3) Remove the accessory drive belt.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove right front fender inner splash shield.
(3) Install power steering belt remover tool on
crankshaft damper (Fig. 6).
(4) Rotate engine clockwise to remove belt (Fig. 7).
INSTALLATION-ACCESSORY DRIVE BELT
(1) Install the accessory drive belt in proper posi-
tion (Fig. 8).
(2) Unlock belt tensioner by removing punch and
apply tension to accessory drive belt (Fig. 9).
(3) Install the power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
RGACCESSORY DRIVE7a-11
DRIVE BELTS (Continued)
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