2001 DODGE TOWN AND COUNTRY check engine

(19) Remove exhaust manifold heat shield (Fig.
18).
(20) Remove exhaust manifold retaining nuts (Fig.
18).
(21) Slide exhaust manifold and turbocharger off of
exhaust manifold studs (Fig. 18).
(22) Remove cylinder head bolts.
(23) Remove cylinder head assembly from engine
block (Fig. 19).CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
exhaust manifold and engine cylinder head mating
surfaces. Remove all gasket material and carbon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
Fig. 17 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
Fig. 18 EXHAUST MANIFOLD AND
TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY LINE BANJO FITTING
2 - WASHER
3 - EXHAUST MANIFOLD GASKET
4 - WASHER
5 - HEAT SHIELD RETAINING BOLTS
6 - TURBOCHARGER
7 - LIFT HOOK
8 - LIFT HOOK RETAINING BOLTS
9 - SPACERS
10 - EXHAUST MANIFOLD RETAINING NUTS
11 - TURBOCHARGER OIL RETURN HOSE
12 - CLAMPS
13 - EXHAUST MANIFOLD STUD
RGENGINE 2.5L TURBO DIESEL9a-21
CYLINDER HEAD (Continued)
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INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces.
The minimum cylinder head thickness is 89.95mm
(3.541 in.).
INSTALLATION
CAUTION: Piston protrusion must be measured to
determine cylinder head gasket thickness if one or
more cylinder liners have benn replaced (Refer to 9
- ENGINE/CYLINDER HEAD - STANDARD PROCE-
DURE).
NOTE: If cylinder liner(s) have not been removed,
the same thickness head gasket that was removed
can be used.(1) Clean and inspect gasket mating surfaces.
(2) Position correct head gasket on engine block.
(3) Place cylinder head on engine block (Fig. 19).
CAUTION: New cylinder head bolts must be uesd.
(4) Tighten cylinder head bolts following procedure
below.
Cylinder Head Bolt Torquing Procedure
(1) Lubricate cylinder head bolts with engine oil.
(2) Torque bolts to 30N´m in numerical starting
with bolt #1 (Fig. 20).
(3) Tighten all bolts an additional 50É, starting
with bolt #4 then 5-6-7-8-9-10-1-2-3-11-12-13-14-15-
16-17-18 (Fig. 20).
(4) Finally tighten all bolts an additional 75É in
numerical order starting with bolt #1 (Fig. 20).
(5) Slide exhaust manifold and turbocharger on
exhaust manifold studs (Fig. 18).
(6) Install exhaust manifold retaining nuts. Torque
nuts to 32.4N´m.
(7) Install exhaust manifold heat shield (Fig. 18).
Torque bolts to 27.5N´m.
(8) Install turbocharger outlet to charge air cooler
pipe (Fig. 17).
(9) Install thermostat housing to upper radiator
hose pipe (Fig. 17). Install retaining bolt and torque
to 47.1N´m.
(10) Install coolant recovery pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - INSTALLATION).
Fig. 19 CYLINDER HEAD ASSEMBLY
1 - VALVE SPRING
2 - CYLINDER HEAD BOLT
3 - GLOW PLUG
4 - COOLANT TEMPERATURE SENSOR
5 - CYLINDER HEAD ALIGNMENT DOWEL
6 - CYLINDER BLOCK
7 - CYLINDER LINER
8 - ENGINE BLOCK DECK
9 - CYLINDER HEAD GASKET
10 - CYLINDER HEAD
11 - ROCKER ARM AND LIFTER ASSEMBLY
Fig. 20 CYLINDER HEAD TORQUE SEQUENCE
9a - 22 ENGINE 2.5L TURBO DIESELRG
CYLINDER HEAD (Continued)
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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 crankshaft all the way to the front of
its travel.
(3) Zero the dial indicator.
(4) Move the crankshaft all the way to the rear
and read dial indicator. For crankshaft end play
clearances (Refer to 9 - ENGINE - SPECIFICA-
TIONS).
REMOVAL
(1) Remove engine from vehicle (Refer to 9 -
ENGINE - REMOVAL).
(2) Mount engine on an engine stand.
(3) Drain engine oil and remove oil filter.
(4) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(5) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(6) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(7) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(8) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(9) Remove flywheel.
(10) Remove rear main bearing support/adapter
plate retaining bolts and remove adapter plate (Fig.
37).
(11) Remove rear main bearing support by thread-
ing two retaining bolts in holes provided. Tighten
bolts equally to push main bearing support out of
block (Fig. 38).
(12) Remove front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(13) Remove crankshaft sprocket.
Fig. 36 CHECKING CRANKSHAFT END PLAY
1 - DIAL INDICATOR
2 - ADAPTER PLATE
3 - REAR MAIN BEARING SUPPORT
4 - SEALING RING
5 - SEALING RING
6 - ALIGNMENT PIN
7 - CRANKSHAFT
8 - RELUCTOR WHEEL
9 - RELUCTOR WHEEL RETAINING BOLT
10 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
11 - FLYWHEEL
12 - FLYWHEEL BOLTS
9a - 32 ENGINE 2.5L TURBO DIESELRG
CRANKSHAFT (Continued)
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(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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(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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cylinder bore. Check gap with feeler gauge (Fig. 49).
Top compression ring gap .30 to .45mm (.0118 to
.0177 in.). Second compression ring gap .30 to .45mm
(.0118 to .0177 in.). Oil control ring gap .25 to .50mm
(.0098 to .0196 in.).
(2) If ring gaps exceed dimension given, new rings
or cylinder liners must be fitted. Keep piston rings in
piston sets.
(3) Check piston ring to groove clearance (Fig. 50).
Top compression ring gap .080 to .130mm (.0031 to
.0051 in.). Second compression ring gap .070 to
.110mm (.0027 to .0043 in.). Oil control ring gap .040
to .080mm (.0015 to .0031 in.).REMOVAL
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) Raise vehicle on hoist.
(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove oil pump pickup tube.(Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - REMOVAL)
(6) Remove balance shaft assembly (Refer to 9 -
ENGINE/VALVE TIMING/BALANCE SHAFT -
REMOVAL).
(7) Remove top ridge of cylinder bores with a ridge
reamer before removing pistons from cylinder block.
Be sure to keep top of pistons covered during
this operation.
(8) Piston and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
NOTE: Be careful not to nick or scratch crankshaft
journals
(9) After removal, install bearing cap on the mat-
ing rod and mark pistons with matching cylinder
number when removed from engine block.
PISTON PIN - REMOVAL
(1) Secure connecting rods in a soft jawed vice.
(2) Remove 2 snap rings securing piston pin (Fig.
51).
(3) Push piston pin out of piston and connecting
rod (Fig. 51).
PISTON RING - REMOVAL
(1) ID mark on face of top and second piston rings
must point toward piston crown.
(2) Using a suitable ring expander, remove top and
second piston rings (Fig. 52).
(3) Remove upper oil ring side rail, lower oil ring
side rail and then the oil expander from piston.
(4) Carefully clean carbon from piston crowns,
skirts and ring grooves ensuring the 4 oil holes in
the oil control ring groove are clear.
INSPECTION
PISTONS
(1) Piston Diameter: Size: 91.912-91.928mm
(3.6185-3.6192 in.) Maximum wear limit .05mm
(.0019 in.).
(2) Check piston pin bores in piston for roundness.
Make 3 checks at 120É intervals. Maximum out of
roundness .05mm (.0019in.).
(3) The piston diameter should be measured
approximately 15 mm (.590 in.) up from the base.
Fig. 49 RING END GAP MEASUREMENT
1 - FEELER GAUGE
Fig. 50 PISTON RING TO GROOVE CLEARANCE
9a - 38 ENGINE 2.5L TURBO DIESELRG
PISTON & CONNECTING ROD (Continued)
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(4) Skirt wear should not exceed 0.1 mm (.00039
in.).
(5) The clearance between the cylinder liner and
piston should not exceed 0.065-0.083 mm
(.0025-.0032 in.).
(6) Make sure the weight of the pistons does not
differ by more than 5 g.
CONNECTING RODS
(1) Assemble bearing shells and bearing caps to
their respective connecting rods ensuring that the
serrations on the cap and reference marks are
aligned.
(2) Tighten bearing cap bolts to 29 N´m (21 ft. lbs.)
plus 60É.
(3) Check and record internal diameter of crank
end of connecting rod.
NOTE: When changing connecting rods, all four
must have the same weight and be stamped with
the same number. Replacement connecting rods
will only be supplied in sets of four.
Connecting rods are supplied in sets of four since
they all must be of the same weight category. Max
allowable weight difference is 18 gr.
NOTE: On one side of the big end of the con-rod
there is a two-digit number which refers to the
weight category. On the other side of the big end
there is a four digit number on both the rod and the
cap. These numbers must both face the injection
pump side of the block. Lightly heat the piston in
oven. Insert piston pin in position and secure it
with provided snap rings.
The Four digit numbers marked on con rod
big end and rod cap must be on the same side
as the injection pump.After having coated threads
with Molyguard, tighten con rod bolts to 29 N´m (21
ft. lbs.) plus 60É.
Fig. 51 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
Fig. 52 PISTON RINGS - REMOVAL/INSTALLATION
RGENGINE 2.5L TURBO DIESEL9a-39
PISTON & CONNECTING ROD (Continued)
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PISTON PINS
(1) Measure the diameter of piston pin in the cen-
ter and both ends.
(2) Piston pin diameter is 29.992 to 29.996mm
(1.1807 to 1.1809 in.).
INSTALLATION
PISTON PIN INSTALLATION
(1) Secure connecting rod in soft jawed vice.
(2) Lubricate piston pin and piston with clean
engine oil.
(3) Position piston on connecting rod (Fig. 53).
CAUTION: Ensure arrow on piston crown and the
bearing cap numbers on the connecting rod are on
the opposite side.
(4) Install piston pin (Fig. 53).
(5) Install clips in piston to retain piston pin (Fig.
53).
(6) Remove connecting rod from vice.
PISTON RINGS - INSTALLATION
(1) Install rings on the pistons using a suitable
ring expander (Fig. 54).
(2) Top compression ring is tapered and chromium
plated. The second ring is of the scraper type and
must be installed with scraping edge facing bottom of
the piston. The third is an oil control ring. Ring gaps
must be positioned, before inserting piston into the
liners, as follows.
(3) Top ring gap must be positioned at the #3 posi-
tion (looking at the piston crown from above) (Fig.
55).
(4) Second piston ring gap should be positioned at
the #1 position (Fig. 55).
(5) Oil control ring gap should be positioned at the
#2 position (Fig. 55).
(6) When assembling pistons check that compo-
nents are installed in the same position as before dis-
assembly, determined by the numbers stamped on
the crown of individual pistons. Engine cylinders are
numbered starting from gear train end of the engine.
Face arrow on top of piston toward front of
engine. Therefore, the numbers stamped on connect-
ing rod big end should face toward the injection
pump side of engine. To insert piston into cylinder
use a ring compressor as shown in (Fig. 56).
INSTALLATION
(1) Before installing pistons, and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 55).
Fig. 53 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
9a - 40 ENGINE 2.5L TURBO DIESELRG
PISTON & CONNECTING ROD (Continued)
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