2001 DODGE TOWN AND COUNTRY Service Manual

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Page 1345 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual HYDRAULIC LIFTERS
DESCRIPTION
Valve lash is controlled by hydraulic tappets
located inside the cylinder head, in tappet bores
below the camshafts (Fig. 32).
REMOVAL
(1) Disconnect negative battery cab

Page 1346 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual INSPECTION
Clean each lifter assembly in cleaning solvent to
remove all varnish and sludge deposits. Inspect for
indications of scuffing on the side and base of each
lifter body.
INSTALLATION
(1) Inst

Page 1347 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual STANDARD PROCEDURE - CHECKING
CRANKSHAFT END PLAY
(1) Mount a dial indicator to a stationary point at
rear of engine. Locate the probe perpendicular
against the flywheel (Fig. 36).
(2) Move the cranks

Page 1348 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual (14) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(15) Remove oil pump pickup tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
(16) Remove balance shaft assembly (Re

Page 1349 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual (5) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(6) Install rear main bearing support in engine
block.Be sure to align oil hole in rear main
bearing supp

(5) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(6) Install rear main bearing support in engine
block.Be sure to align oil hole in rear main
bearing support with hole in block.
(7) Install adapter plate and retaining bolts (Fig.
37). Torque bolts to 27.5N´m.
(8) Install flywheel.
(9) Install piston and connecting rod assemblies
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON &
CONNECTING ROD - INSTALLATION).
(10) Install oil jets (Refer to 9 - ENGINE/LUBRI-
CATION/OIL JET - INSTALLATION).
(11) Install balance shaft assembly (Refer to 9 -
ENGINE/VALVE TIMING/BALANCE SHAFT -
INSTALLATION).
(12) Install oil pump pickup tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).
(13) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(14) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(15) Install cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - INSTALLATION).
(16) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(17) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .(18) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(19) Install engine in vehicle.
(20) Fill engine oil with proper oil to correct level.
CYLINDER LINERS
DESCRIPTION
The cylinder wall liner used on this engine is of
the wet design. O-rings are used to seal the liner to
the engine block.
REMOVAL
(1) Remove engine from vehicle.
(2) With engine completely disassembled, use spe-
cial tool VM.1001 to remove liner assembly (Fig. 41).
(3) Tighten bolt on VM.1001 to remove liner from
block (Fig. 42).
(4) Remove shims from cylinder liner or cylinder
block recess. Keep shims with each cylinder liner.
INSPECTION
The cylinder walls should be checked for out-of-
round and taper with a dial bore gauge. The cylinder
bore out-of-round is 0.100 mm (.0039 in.) maximum
Fig. 40 CRANKSHAFT SUPPORT RETAINERS
1 - CRANKSHAFT SUPPORT RETAINERS
2 - ENGINE BLOCK
Fig. 41 CYLINDER LINER REMOVER
9a - 34 ENGINE 2.5L TURBO DIESELRG
CRANKSHAFT (Continued)
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Page 1350 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual and cylinder bore taper is 0.100 mm (.0039 in.) max-
imum. If the cylinder walls are badly scuffed or
scored, new liners should be installed and honed, and
new pistons and rings fitted.
Measure the cy

Page 1351 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual (8) Fit the liners in the crankcase making sure
that the shim is positioned correctly in the seat. Lock
the liners in position using special tool (VM.1076)
and bolts (Fig. 45). Clean the residual LOCT

(8) Fit the liners in the crankcase making sure
that the shim is positioned correctly in the seat. Lock
the liners in position using special tool (VM.1076)
and bolts (Fig. 45). Clean the residual LOCTITE on
the upper surface of the block deck.
(9) Recheck the liner protrusion. It should be 0.01
- 0.06 mm.
NOTE: A period of six hours must elapse between
the liners being installed and engine start-up. If
engine assembly is not continued after liner instal-
lation, the liners need to be clamped for twelve
hours minimum.
(10) Reassemble engine.
(11) Install engine in vehicle.
INTERNAL VACUUM PUMP
DESCRIPTION
The diesel engine uses a internal vacuum pump.
This vacuum pump is mounted in the front of the
engine block under the engine front cover (Fig. 46).
The vacuum pump is driven by a sprocket on the
crankshaft.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(6) Remove vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(7) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(8) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(9) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
NOTE: Crankshaft hub has LHD thread.
(10) Remove crankshaft hub.
(11) Remove front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(12) Remove crankshaft sprocket (Fig. 47).
(13) Remove vacuum pump (Fig. 47).
INSTALLATION
(1) Lubricate vacuum pump components and
install in engine block (Fig. 47). Torque bolts to
10.8N´m.
(2) Install crankshaft sprocket (Fig. 47). Torque
bolts to 10.8N´m.
(3) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
Fig. 45 LINER CLAMP LOCATION
1 - ENGINE BLOCK
2 - LINER RETAINER VM.1076
3 - CYLINDER LINER
Fig. 46 VACUUM PUMP
9a - 36 ENGINE 2.5L TURBO DIESELRG
CYLINDER LINERS (Continued)
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Page 1352 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual (4) Install front crankshaft hub. Torque bolt to
304N´m.
(5) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(6) Install timing belt (R

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