2001 DODGE TOWN AND COUNTRY Service Manual

fuel cap release bonnet recommended oil fuse chart wheelbase maintenance reset

Page 1385 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual CROSS-OVER PIPE
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fasteners attaching the left bank
manifold connection to cross-over pipe (Fig. 6).
(3) Raise vehicle and remove the l

Page 1386 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system floor pan heat shields on cars so
equipped. Light over spray near the edges is
permitted. Application of co

Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system floor pan heat shields on cars so
equipped. Light over spray near the edges is
permitted. Application of coating will greatly
reduce the efficiency of the heat shields result-
ing in excessive floor pan temperatures and
objectionable fumes.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove fasteners attaching applicable heat
shield (Fig. 7), (Fig. 8), or (Fig. 9).
(3) Remove heat shield(s).
INSTALLATION
(1) Position heat shield(s) to underbody.
(2) Install heat shield fasteners and tighten to 2.6
N´m (23 in. lbs.) (Fig. 7), (Fig. 8), or (Fig. 9).
(3) Lower vehicle.
MUFFLER
REMOVAL
(1) Raise vehicle on a body contact type hoist.
NOTE: To provide removal clearance between muf-
fler/resonator pipe and rear axle parts, the rear sus-
pension must be relieved of all body weight.
(2) Apply a penetrating oil to clamp nuts of com-
ponent requiring removal.
CAUTION: When servicing the exhaust system, care
must be exercised not to dent or bend the bellows
of the flex-joint. Should this occur, the flex-joint willeventually fail, requiring replacement of the cata-
lytic converter.
(3) Disconnect the right side axle half shaft from
the rear differential module (AWD equipped only).
(4) Loosen the band clamp (Fig. 10) at the muffler
to converter pipe connection.
(5) Remove the exhaust hangers to body screws
(Fig. 10).
(6) Separate muffler pipe from converter pipe.
(7) Remove muffler/resonator assembly by moving
assembly forward and guiding the resonator through
the rear axle to body opening.
(8) Clean ends of pipes or muffler to assure mat-
ing of all parts. Discard broken or worn insulators,
rusted clamps, supports and attaching parts.When
replacement is required on any component of
the exhaust system, it is important that original
equipment parts (or equivalent) be used for the
following conditions:
²Ensure proper alignment with other components
in the system.
²Provide acceptable exhaust noise levels.
²Provide proper exhaust system back pressure for
maintaining emission and performance levels.
INSTALLATION
(1) Install the muffler/resonator assembly by guid-
ing resonator between the rear axle and body.
(2) Connect the muffler pipe to the converter pipe
but do not tighten band clamp (Fig. 10).
(3) Position hangers to body and install screws
starting at the resonator working forward (Fig. 10).
Tighten hanger screws to 28 N´m (250 in. lbs.).
(4) Insert muffler pipe into catalytic converter pipe
until the hangers are positioned as shown in (Fig. 11)
CAUTION: Band clamps should never be tightened
such that the two sides of the clamps are bottomed
out against the center hourglass shaped center
block. Once this occurs, the clamp band has been
stretched and has lost its clamping force and must
be replaced.
To replace the band clamp; remove the nut and peel
back the ends of the clamp until spot weld breaks.
Clean remaining spot weld from the pipe using a
file or grinder until surface is smooth.
NOTE: Maintain proper clamp orientation when
replacing with new clamp.
(5) Tighten the band clamp to 55 N´m (40 ft. lbs.)
(Fig. 12).
(6) Connect the right side half shaft to the rear
differential module (AWD equipped only).
Fig. 9 RESONATOR PIPE HEAT SHIELD
1 - SCREW (QTY. 3)
2 - HEAT SHIELD - RESONATOR PIPE
3 - MUFFLER
RSEXHAUST SYSTEM11-7
HEAT SHIELDS (Continued)
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Page 1387 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual RESONATOR
REMOVAL
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
REMOVAL)
INSTALLATION
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
INSTALLATION)
Fig. 10 Exhaust System - Typical (All Vehicles)
1 - SCREW

Page 1388 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual EXHAUST SYSTEM AND TURBOCHARGER
TABLE OF CONTENTS
page page
EXHAUST SYSTEM AND TURBOCHARGER
DESCRIPTION............................1
SPECIFICATIONS.........................1
TURBOCHARGER SYSTEM
DESCRI

EXHAUST SYSTEM AND TURBOCHARGER
TABLE OF CONTENTS
page page
EXHAUST SYSTEM AND TURBOCHARGER
DESCRIPTION............................1
SPECIFICATIONS.........................1
TURBOCHARGER SYSTEM
DESCRIPTION............................2
OPERATION.............................2
TURBOCHARGER
REMOVAL...............................4CLEANING...............................5
INSTALLATION............................5
HEAT SHIELDS
REMOVAL...............................5
INSTALLATION............................6
EXHAUST SYSTEM AND
TURBOCHARGER
DESCRIPTION
The basic exhaust system consists of an engine
exhaust manifold, turbocharger, exhaust down pipe,
exhaust pipe, exhaust heat shield(s), muffler and
exhaust tailpipe
The exhaust system uses a single muffler.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the sys-
tem contacts any body panel, it will transfer objec-
tionable noises originating from the engine to the
body.
When inspecting an exhaust system, critically
inspect for cracked or loose joints, stripped screw orbolt threads, corrosion damage and worn, cracked or
broken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to
repair.
When replacement is required, use original equip-
ment parts (or equivalent). This will assure proper
alignment and provide acceptable exhaust noise lev-
els.
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
SPECIFICATIONS
SPECIFICATIONS - TORQUE
2.5L DIESEL - TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Turbocharger Oil Feed
Line Fitting24.5 18 215
Exhaust Manifold Nuts 32.4 24 Ð
Exhaust Manifold Heat
shield Bolts27.5 21 Ð
Turbocharger Downpipe
Nuts32.4 24 Ð
Turbocharger Bracket
Bolts47.1 35 Ð
Turbocharger to Exhaust
Manifold Nuts32.4 24 Ð
RGEXHAUST SYSTEM AND TURBOCHARGER11a-1
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Page 1389 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual TURBOCHARGER SYSTEM
DESCRIPTION
CAUTION: The turbocharger is a performance part
and must not be tampered with. The wastegate
bracket is an integral part of the turbocharger. Tam-
pering with the waste

TURBOCHARGER SYSTEM
DESCRIPTION
CAUTION: The turbocharger is a performance part
and must not be tampered with. The wastegate
bracket is an integral part of the turbocharger. Tam-
pering with the wastegate components can reduce
durability by increasing cylinder pressure and ther-
mal loading due to incorrect inlet and exhaust man-
ifold pressure. Poor fuel economy and failure to
meet regulatory emissions laws may result. Increas-
ing the turbocharger boost WILL NOT increase
engine power.
The turbocharger is an exhaust-driven super-
charger which increases the pressure and density of
the air entering the engine. With the increase of air
entering the engine, more fuel can be injected into
the cylinders, which creates more power during com-
bustion.
The turbocharger assembly consists of four (4)
major component systems (Fig. 1) (Fig. 2):
²Turbine section
²Compressor section
²Bearing housing
²Wastegate
OPERATION
Exhaust gas pressure and energy drive the tur-
bine, which in turn drives a centrifugal compressor
that compresses the inlet air, and forces the air into
the engine through the charge air cooler and plumb-
ing. Since heat is a by-product of this compression,
the air must pass through a charge air cooler to cool
the incoming air and maintain power and efficiency.
Increasing air flow to the engine provides:
²Improved engine performance
²Lower exhaust smoke density
²Improved operating economy
²Altitude compensation
²Noise reduction.
The turbocharger also uses a wastegate (Fig. 3),
which regulates intake manifold air pressure and
prevents over boosting at high engine speeds. When
the wastegate valve is closed, all of the exhaust gases
flow through the turbine wheel. As the intake mani-
fold pressure increases, the wastegate actuator opens
the valve, diverting some of the exhaust gases away
from the turbine wheel. This limits turbine shaft
speed and air output from the impeller.
Fig. 1 Turbocharger Operation
1 - TURBINE SECTION
2 - EXHAUST GAS
3 - BEARING HOUSING
4 - COMPRESSOR SECTION
5 - INLET AIR
6 - COMPRESSED AIR TO ENGINE
7 - EXHAUST GAS
8 - EXHAUST GAS TO EXHAUST PIPE
Fig. 2 Turbocharger Wastegate Actuator
1 - TURBOCHARGER
2 - DIAPHRAGM
3 - WASTE GATE ACTUATOR
11a - 2 EXHAUST SYSTEM AND TURBOCHARGERRG
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Page 1390 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual The turbocharger is lubricated by engine oil that is
pressurized, cooled, and filtered. The oil is delivered
to the turbocharger by a supply line that is tapped
into the oil filter head. The oil trave

Page 1391 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual TURBOCHARGER
REMOVAL
The exhaust manifold and turbocharger cannot be
remove with the engine in vehicle.
(1) Remove engine from vehicle and mount on
engine stand (Refer to 9 - ENGINE - REMOVAL) .
(2) R

Page 1392 of 2321

DODGE TOWN AND COUNTRY 2001 Service Manual (8) With exhaust manifold and turbocharger
assembly on work bench, remove turbocharger to
exhaust manifold retaining bolts. Separate exhaust
manifold and turbocharger.
CLEANING
All old gaskets should

(8) With exhaust manifold and turbocharger
assembly on work bench, remove turbocharger to
exhaust manifold retaining bolts. Separate exhaust
manifold and turbocharger.
CLEANING
All old gaskets should be inspected for any tears or
signs of prior leakage. If any gaskets show such indi-
cations, they should be replaced with new gaskets.
All gasket mating surfaces must be cleaned of old
gasket material to produce a smooth and dirt free
sealing surface for the new gasket.
INSTALLATION
(1) Connect exhaust manifold and turbocharger.
Torque nuts to 32.4N´m.
(2) Position new exhaust manifol gasket on
exhaust manifol studs (Fig. 6).
(3) Install exhaust manifold and turbocharger on
engine (Fig. 6). Torque nuts to 32.4N´m.
(4) Connect turbocharger oil supply and return
lines at turbocharger (Fig. 6). Torque oil supply line
to 24.5N´m.
(5) Install exhaust manifold shield (Fig. 6). Torque
bolts to 27.5N´m.
(6) Install engine lift hook (Fig. 6). Torque bolts to
32.4N´m.
(7) Install thermostat to upper radiator hose tube
and turbocharger outlet tube (Fig. 5).
(8) Install engine in vehicle (Refer to 9 - ENGINE
- INSTALLATION).
HEAT SHIELDS
REMOVAL
(1) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Partially drain cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(4) Remove thermostat housing to upper radiator
hose tube (Fig. 7).
(5) Remove exhaust manifold heat shield retaining
bolts and remove shield (Fig. 8).
Fig. 7 TURBOCHARGER AND COOLANT PIPES
1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT
2 - TURBOCHARGER OUTLET PIPE
3 - ADAPTER HOSE
4 - HEAT SHIELD
5 - HOSE CLAMPS
6 - TURBOCHARGER INLET PIPE RETAINING BOLT
7 - TURBOCHARGER INLET PIPE
8 - ADAPTER HOSE
9 - HOSE CLAMPS
10 - CLAMP
11 - EGR VALVE TO INTAKE AIR INLET PIPE
12 - CLAMP
13 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE
PIPE
RGEXHAUST SYSTEM AND TURBOCHARGER11a-5
TURBOCHARGER (Continued)
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