2001 DODGE TOWN AND COUNTRY Service Manual

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Page 1273 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual (3) Install seal using Special Tool C-4992-1 until
seal is flush with cover. (Fig. 64).
(4) Install crankshaft damper. (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
(5) Install ac

Page 1274 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
(1) Place Special Tool

Page 1275 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual FLEX PLATE
REMOVAL
(1) Remove the transaxle. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 31TH -
REMOVAL) (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/AUTOMATIC - 41TE - REMOVAL)
(2) Remove flex pla

Page 1276 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual OIL LEVEL TOO HIGH
If oil level is above the MAX mark on dipstick, it is
possible for the connecting rods to dip into the oil
while engine is running and create foaming. Foam in
oil pan would be fed t

OIL LEVEL TOO HIGH
If oil level is above the MAX mark on dipstick, it is
possible for the connecting rods to dip into the oil
while engine is running and create foaming. Foam in
oil pan would be fed to the hydraulic lifters by the oil
pump causing them to become soft and allow valves
to seat noisily.
OIL LEVEL TOO LOW
Low oil level may allow pump to take in air which
when fed to the lifters it causes them to become soft
and allows valves to seat noisily. Any leaks on intake
side of pump, through which air can be drawn, will
create the same lifter noise. Check the lubrication
system from the intake strainer to the oil pump
cover, including the relief valve retainer cap. When
lifter noise is due to aeration, it may be intermittent
or constant, and usually more than one lifter will be
noisy. When oil level and leaks have been corrected,
the engine should be operated at fast idle to allow all
of the air inside of the lifters to be bled out.
VALVE TRAIN NOISE
To determine source of valve train noise, operate
engine at idle with cylinder head covers removed and
listen for source of the noise.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy lifters. If such is the
case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
Valve lifter noise ranges from light noise to a
heavy click. A light noise is usually caused by exces-
sive leak-down around the unit plunger which will
necessitate replacing the lifter, or by the plunger par-
tially sticking in the lifter body cylinder. A heavy
click is caused either by a lifter check valve not seat-
ing, or by foreign particles becoming wedged between
the plunger and the lifter body causing the plunger
to stick in the down position. This heavy click will be
accompanied by excessive clearance between the
valve stem and rocker arm as valve closes. In either
case, lifter assembly should be removed for inspec-
tion.
REMOVAL
(1) Remove the cylinder head(s). (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL)
(2) Remove the yoke retainer and aligning yokes
(Fig. 71).
(3) Remove the hydraulic lifters. If necessary use
Special Tool C-4129, or equivalent to remove liftersfrom bores. If lifters are to be reused, identify each
lifter to ensure installation in original location.
INSTALLATION
(1) Lubricate the lifters with engine oil.
NOTE: Position the lifter in bore with the lubrication
hole facing upward (Fig. 70).
(2) Install the hydraulic lifters with the lubrication
hole facing upward towards middle of block (Fig. 70).
Install lifters in original positions, if reused.
(3) Install lifter aligning yokes (Fig. 71).
(4) Install yoke retainer and torque screws to 12
N´m (105 in. lbs.) (Fig. 71).
(5) Install the cylinder heads. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION)
(6) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic lifters have filled with oil and have
become quiet.
PISTON & CONNECTING ROD
DESCRIPTION
The pistons are made of cast aluminum alloy and
are a strutless, short skirt design. The piston rings
consist of two compression rings and a three piece oil
ring. Piston pins connect the piston to the forged
steel connecting rods. The piston pins are a press fit
into the connecting rod.
Fig. 70 LIFTER LUBRICATION HOLE
RSENGINE 3.3/3.8L9 - 119
HYDRAULIC LIFTERS (CAM IN BLOCK) (Continued)
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Page 1277 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual OPERATION
The piston and connecting rod is the link between
the combustion force to the crankshaft.
STANDARD PROCEDURES - FITTING
CONNECTING RODS
The bearing caps are not interchangeable or
reversible

Page 1278 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual STANDARD PROCEDURES - FITTING PISTONS
The piston and cylinder wall must be clean and
dry. Piston diameter should be measured 90 degrees
to piston pin at size location shown in (Fig. 74). Cyl-
inder bo

Page 1279 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual INSTALLATION
(1) Before installing pistons and connecting rod
assemblies into the bore, ensure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 78).
(2)

INSTALLATION
(1) Before installing pistons and connecting rod
assemblies into the bore, ensure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 78).
(2) Before installing the ring compressor, ensure
the oil ring expander ends are butted and the rail
gaps located as shown in (Fig. 78).
(3) Lubricate the piston and rings with clean
engine oil. Position a ring compressor over the piston
and rings, and tighten the compressor (Fig. 79).Be
sure position of rings does not change during
this operation.(4) Position upper bearing onto connecting rod.
Lubricate bearing with oil.
(5) Install connecting rod bolt protectors (rubber
hose or equivalent) on the connecting rod bolts (Fig.
79).
(6) The pistons are marked with a ªFº located near
the piston pin. Install piston with this mark posi-
tioned to front of engine on both cylinder banks. The
connecting rod oil squirt hole faces the major thrust
(right) side of the engine block (Fig. 80).
(7) Rotate crankshaft until the connecting rod
journal is located in the center of the cylinder bore.
Insert connecting rod and piston into cylinder bore.
Carefully guide connecting rod over the crankshaft
journal (Fig. 79).
(8) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(9) Install lower bearing shell and connecting rod
cap (Fig. 79). Install nuts on cleaned and oiled rod
bolts and tighten to 54 N´m (40 ft. lbs.) PLUS
1¤4
turn.
(10) Repeat procedure for each piston and connect-
ing rod installation.
(11) Install the cylinder heads. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION)
(12) Install the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION)
(13) Fill engine crankcase with proper oil to cor-
rect level.
(14) Connect negative cable to battery.Fig. 78 Piston Ring End Gap Position
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
9 - 122 ENGINE 3.3/3.8LRS
PISTON & CONNECTING ROD (Continued)
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Page 1280 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual Fig. 79 PISTON AND CONNECTING ROD INSTALLATION
1 - RING - OIL CONTROL 7 - CAP - CONNECTING ROD
2 - RING - NO. 2 COMPRESSION 8 - BEARING - CONNECTING ROD LOWER
3 - RING - NO. 1 COMPRESSION 9 - CRANKSHA

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