2001 DODGE TOWN AND COUNTRY Service Manual

brake rotor clock reset charging jack points oil filter oil capacities

Page 1257 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual (2) Measure the concentricity of valve seat using
dial indicator (Fig. 29). Total runout should not
exceed 0.051 mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat using Prussian blue

(2) Measure the concentricity of valve seat using
dial indicator (Fig. 29). Total runout should not
exceed 0.051 mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat using Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of valve face, lower valve seat with
a 15 degree stone. If the blue is transferred to the
bottom edge of valve face raise valve seat with a 65
degrees stone.
NOTE: Valve seats which are worn or burned can
be reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head must
be replaced.
(4) When seat is properly positioned the width of
intake and exhaust seats should be 1.50±2.00 mm
(0.059±0.078 in.) (Fig. 26).
(5) After grinding the valve seats or faces, install
the valve in cylinder head and check valve installed
height by measuring from valve tip to spring seat
(Fig. 30). Remove valve from cylinder head and grind
valve tip until within specifications. Check valve tip
for scoring. The tip chamfer should be reground (if
necessary) to prevent seal damage when the valve is
installed.
(6) Check the valve spring installed height after
refacing the valve and seat (Fig. 30).If valves
and/or seats are reground, measure the
installed height of springs (Fig. 30), make sure
measurements are taken from top of spring
seat to the bottom surface of spring retainer. If
height is greater than specifications, install a0.794 mm (0.0312 in.) spacer in head counter-
bore to bring spring height back within specifi-
cations.
REMOVAL
(1) With cylinder head removed, compress valve
springs using Valve Spring Compressor Tool
C-3422-B with adapter 6412.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
CLEANING
(1) Clean all valves thoroughly and discard
burned, warped and cracked valves.
INSPECTION
VALVES
(1) Clean and inspect valves thoroughly. Replace
burned, warped and cracked valves.
(2) Measure valve stems for wear (Fig. 31). For
valve specifications, (Refer to 9 - ENGINE - SPECI-
FICATIONS).
NOTE: Valve stems are chrome plated and should
not be polished (Fig. 31).
Fig. 29 Measurement of Valve Seat Runout
1 - DIAL INDICATOR
Fig. 30 Checking Valve and Spring Installed Height
1 - SPRING RETAINER
2 - VALVE INSTALLED HEIGHT* - 48.1±49.7 mm (1.89±1.95 in.)
3 - CYINDER HEAD SURFACE
4 - SPRING INSTALLED HEIGHT* - 41.1±42.7 mm (1.61±1.68 in.)
*(MEASURED FROM TOP OF SPRING SEAT)
9 - 100 ENGINE 3.3/3.8LRS
INTAKE/EXHAUST VALVES & SEATS (Continued)
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Page 1258 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Measure valve stem-to-guide clearance as fol-
lows:
(3) Install valve into cylinder h

VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Measure valve stem-to-guide clearance as fol-
lows:
(3) Install valve into cylinder head so it is 15 mm
(0.590 inch.) off the valve seat. A small piece of hose
may be used to hold valve in place.
(4) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 32).
(5) Move valve to and from the indicator. For cler-
ance specifications, (Refer to 9 - ENGINE - SPECIFI-
CATIONS).
NOTE: Replace cylinder head if stem-to-guide clear-
ance exceeds specifications, or if guide is loose in
cylinder head.
INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) Install valve spring seat on head (Fig. 34).
(3) Install new seals on all valve stems and over
valve guides (Fig. 34). Install valve springs and valve
retainers (Fig. 34).
(4) Install the valve springs. (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE SPRINGS -
INSTALLATION)
VALVE SPRINGS
DESCRIPTION
The valve springs are a bee-hive shaped design
(Fig. 33). The springs are seated on a steel washer on
the cylinder head with retainers and locks retaining
the springs (Fig. 34). The springs are installed with
the smaller diameter against spring retainer (Fig.
33).
OPERATION
The valve spring returns the valve against its seat
for a positive seal of the combustion chamber.
REMOVAL - CYLINDER HEAD OFF
(1) With the cylinder head on a bench, position
Special Tool C-3422-D with 8464 Adapter on the
valve and spring retainer (Fig. 35).
(2) Compress the spring only enough to remove the
valve retainer locks.
(3) Slowly release the spring tension and remove
the valve spring and retainer.
Fig. 31 Intake and Exhaust Valves
1 - MARGIN
2-FACE
3 - STEM
4 - VALVE SPRING RETAINER LOCK GROOVES
Fig. 32 Measuring Valve Guide Wear - Typical
Fig. 33 Valve Spring
1 - VALVE SPRING (TOP - SMALLER DIAMETER)
RSENGINE 3.3/3.8L9 - 101
INTAKE/EXHAUST VALVES & SEATS (Continued)
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Page 1259 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual (4) For removal of the valve stem seal (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE STEM SEALS -
REMOVAL).
REMOVAL - CYLINDER HEAD ON
(1) Disconnect negative cable from battery.
(2) Remove spark plug wire

Page 1260 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual (8) Locate the forcing screw and spring retainer
adapter assembly over the spring requiring removal
(Fig. 36).
(9) Slowly turn the forcing screw clockwise (com-
pressing the valve spring) until the va

(8) Locate the forcing screw and spring retainer
adapter assembly over the spring requiring removal
(Fig. 36).
(9) Slowly turn the forcing screw clockwise (com-
pressing the valve spring) until the valve keepers can
be removed.
(10) Turn forcing screw counterclockwise to relieve
spring tension. Remove retainer and valve spring.
(11) Repeat procedure for each cylinder requiring
valve spring removal.
INSPECTION
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 37).As an example;the compression
length of a spring to be tested is 38.00 mm (1.496
in.). Turn the table of Tool C-647 until surface is in
line with the 38.00 mm (1.496 in.) mark on the
threaded stud and the zero mark on the front. Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Refer to Engine Specifications to obtain
specified height and allowable tensions (Refer to 9 -
ENGINE - SPECIFICATIONS). Replace any springs
that do not meet specifications.
INSTALLATION - CYLINDER HEAD OFF
(1) If removed, install a new valve stem seal.
(Refer to 9 - ENGINE/CYLINDER HEAD/VALVE
STEM SEALS - INSTALLATION)
(2) Position valve spring and retainer on spring
seat.(3) Using Special Tool C-3422-C with 8464 Adapter
(Fig. 35), compress the spring only enough to install
the valve retainer locks.
(4) Slowly release the spring tension. Ensure the
retainer locks are seated properly.
INSTALLATION - CYLINDER HEAD ON
(1)The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as guide.Do Not Force
seal against top of
guide. When installing the valve retainer locks, com-
press the springonly enoughto install the locks.
CAUTION: Do not pinch seal between retainer and
top of valve guide.
(2) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6.Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(3) Remove spark plug adapter tool.
(4) Install rocker arms and shaft assembly. (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
INSTALLATION)
(5) Install cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(6) Install spark plugs and connect wires.
(7) Connect negative cable to battery.
ROCKER ARMS
DESCRIPTION - ROCKER ARMS
The rocker arms are installed on the rocker arm
shaft. The rocker arms and shaft assembly is attached
to the cylinder head with seven bolts and retainers.
The rocker arms are made of stamped steel.
Fig. 36 VALVE SPRING - REMOVE/INSTALL (HEAD ON)
1 - SPECIAL TOOL 8453
2 - BOLTS - SPECIAL TOOL ATTACHING
3 - AIR SUPPLY HOSE ADAPTER
Fig. 37 TESTING VALVE SPRING
1 - SPECIAL TOOL C-647
RSENGINE 3.3/3.8L9 - 103
VALVE SPRINGS (Continued)
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Page 1261 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual DESCRIPTION - PUSHRODS
The pushrods are made of steel and are a hollow
design. The pushrods are positioned between the
hydraulic lifter and the rocker arm.
OPERATION - ROCKER ARMS
The rocker arm pivot

Page 1262 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual DISASSEMBLY - ROCKER ARMS AND SHAFT
CAUTION: Do not attempt to drive the bolt from the
rocker shaft. This can damage the retainer and bolt
assembly.
(1) Remove the rocker arm retainer and bolt by
perf

Page 1263 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual (3) Slowly tighten rocker shaft bolts evenly until
shaft is seated. Tighten bolts to 23 N´m (200 in. lbs.)
(Fig. 41).
(4) Install the cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLIND

(3) Slowly tighten rocker shaft bolts evenly until
shaft is seated. Tighten bolts to 23 N´m (200 in. lbs.)
(Fig. 41).
(4) Install the cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
VALVE STEM SEALS
DESCRIPTION
The valve stem seals are made of Viton rubber. The
seals are positioned over the valve stem and seated
on the valve guide (Fig. 42).
REMOVAL
(1) Remove the valve springs. (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE SPRINGS -
REMOVAL)
(2) Remove the valve stem seal (Fig. 42).
INSTALLATION
(1) Install the valve stem seal squarely over the
valve guide, using the valve stem as a guide (Fig.
42). Do not force the seal against top of the valve
guide.
(2) Install the valve spring. (Refer to 9 - ENGINE/
CYLINDER HEAD/VALVE SPRINGS - INSTALLA-
TION)
ENGINE BLOCK
DESCRIPTION
The cylinder block is made of cast iron and is a
deep skirt design.
STANDARD PROCEDURES - CYLINDER BORE
HONING
(1)Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped with
220 grit stones, is the best tool for this honing proce-
dure. In addition to deglazing, it will reduce taper and
out-of-round as well as removing light scuffing, scor-
ing or scratches. Usually a few strokes will clean up a
bore and maintain the required limits.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20±60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Use a light
honing oil.Do not use engine or transmission oil,
mineral spirits or kerosene.Inspect cylinder walls
after each 20 strokes.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 40-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 43).
(4) A controlled hone motor speed between
200±300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40±60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
Fig. 41 ROCKER ARMS AND SHAFT
1 - ROCKER ARMS AND SHAFT ASSEMBLY
2 - ROCKER SHAFT BOLTS
Fig. 42 Valve Stem Seal
9 - 106 ENGINE 3.3/3.8LRS
ROCKER ARMS (Continued)
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Page 1264 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual CLEANING
Clean cylinder block thoroughly using a suitable
cleaning solvent.
INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If ne

CLEANING
Clean cylinder block thoroughly using a suitable
cleaning solvent.
INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, refer to
Engine Core Plugs for procedures (Refer to 9 -
ENGINE - STANDARD PROCEDURE).
(3) Examine block and cylinder bores for cracks or
fractures.
(4) Check block deck surfaces for flatness. Deck
surface must be within service limit of 0.1 mm (0.004
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
44). (Refer to 9 - ENGINE - SPECIFICATIONS) If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 44). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.Refer to Engine Specifications (Refer to 9 - ENGINE
- SPECIFICATIONS).
CAMSHAFT & BEARINGS (IN
BLOCK)
DESCRIPTION
The nodular iron camshaft is mounted in the
engine block and supported with four steel backed
aluminum bearings (Fig. 45). A thrust plate, located
in front of the first bearing, is bolted to the block and
controls the camshaft end play (Fig. 45). To distin-
guish camshafts between the 3.3L and 3.8L engines,
a cast-in ring is located between the rear bearing
journal and rear lobe (Fig. 46). The 3.3L engine
application is as-cast only. The 3.8L engine applica-
tion the cast ring is machined off.
OPERATION
The camshaft is driven by the crankshaft through
a timing chain and sprockets. The camshaft has pre-
cisely machined (egg-shaped) lobes to provide accu-
rate valve timing and duration.
REMOVAL
(1) Remove the engine assembly from vehicle.
(Refer to 9 - ENGINE - REMOVAL)
Remove the cylinder heads. (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL)
(2) Remove the timing chain and camshaft
sprocket. (Refer to 9 - ENGINE/VALVE TIMING/
Fig. 43 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40É±60É
Fig. 44 Checking Cylinder Bore Size
RSENGINE 3.3/3.8L9 - 107
ENGINE BLOCK (Continued)
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