2001 DODGE TOWN AND COUNTRY torque

(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135, 6710,
6848 and 6909 (Fig. 10).
(5) Remove Special Tools 6912 and 8444.
(6) Lower the vehicle.
(7) Install power steering pump and pressure line
support.(8) Install the generator and wiring harness.
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION)
(9) Raise vehicle.
(10) Attach wiring harness support clip to the dip-
stick tube.
(11) Connect oil pressure switch electrical connec-
tor.
(12) Install the A/C compressor.
(13) Install the water pump pulley.
(14) Connect the radiator lower hose.
(15) Install the accessory drive belt and splash
shield. (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - INSTALLATION)
(16) Connect the engine block heater electrical con-
nector, if equipped.
(17) Connect the knock sensor electrical connector
(3.8L only).
(18) Install the torque converter to flex plate bolts.
(19) Install the transaxle case cover (Fig. 8).
(20) Install the powertrain struts (Fig. 8).
(21) Install the engine rear mount bracket.
(22) Install the engine front mount and bracket
assembly.
(23)AWD equipped;Install the power transfer
unit (PTU).
(24) Install the axle shafts. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(25) Connect exhaust pipe to manifold (Fig. 7).
(26) Install crossmember cradle plate (Fig. 6).
(27) Lower vehicle.
(28) Connect transaxle shift linkage.
(29) Connect transaxle electrical connectors.
(30) Connect transaxle cooler hoses.
(31) Install transaxle dipstick tube and attach
electrical harness clip.
(32) Connect the radiator upper hose.
(33) Connect the A/C lines to compressor.
(34) Connect the A/C compressor electrical connec-
tor.
(35) Evacuate and recharge A/C system.
(36) Connect crankshaft and camshaft position
sensors.
(37) Connect the fuel injector electrical harness
connector and engage clip to support bracket.
(38) Connect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(39) Connect the ground strap to rear of cylinder
head.
(40) Install power steering reservoir.
(41) Engage wire harness clip to engine right side
mount.
(42) Connect the brake booster and speed control
vacuum hoses.
Fig. 11 Right Mount to Engine
1 - BOLT
2 - MOUNT BRACKET
3 - ENGINE RIGHT MOUNT ASSEMBLY
Fig. 12 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
RSENGINE 3.3/3.8L9-85
ENGINE 3.3/3.8L (Continued)
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SPECIFICATIONS - TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Camshaft SprocketÐBolt 54 40 Ð
Camshaft Thrust
PlateÐBolts12 Ð 105
Connecting Rod
CapÐBolts54 +
1¤4
turn40
+1¤4
turnÐ
Crankshaft Main Bearing
CapÐBolts41 +
1¤4
turn30
+1¤4
turnÐ
Crankshaft Oil Seal
Retainer RearÐBolts12 Ð 105
Crankshaft DamperÐBolt 54 40 Ð
Cylinder HeadÐBolts (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Cylinder Head CoverÐ
Bolts12 Ð 105
Flex Plate to Crankshaft 95 70 Ð
Engine Mounting (Refer to 9 - ENGINE/
ENGINE MOUNTING)
Exhaust ManifoldÐBolts 23 Ð 200
Exhaust Crossover
PipeÐBolts54 40 Ð
Intake Manifold -
LowerÐBolts23 Ð 200
Intake Manifold - Lower
Gasket RetainerÐBolts12 Ð 105
Intake Manifold
UpperÐBolts12 Ð 105
Lifter Yoke RetainerÐ
Bolts12 Ð 105
Oil Filter Attaching Fitting 41 30 Ð
Oil Filter 14 10 Ð
Oil Filter AdapterÐBolts 28 Ð 250
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pump Cover
PlateÐScrews12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 Ð 250
Oil Dipstick HousingÐ
Bolts48 35 Ð
Rocker Arm ShaftÐBolts 23 Ð 200
Spark Plug 16 12 Ð
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Timing Chain Case Cover
ÐM8 Bolt 27 20 Ð
ÐM10 Bolt 54 40 Ð
Water PumpÐBolts 12 Ð 105
Water Pump PulleyÐ
Bolts28 Ð 250
SPECIAL TOOLS
3.3/3.8L ENGINE
Dolly, Engine Support 6135
Cradle, Engine Support 6710
Adapter 6909
9 - 90 ENGINE 3.3/3.8LRS
SPECIFICATIONS (Continued)
ProCarManuals.com

DURE) Be careful not to gouge or scratch the alumi-
num head sealing surface.
Clean all engine oil passages.
INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 17).
(4) Cylinder head must be flat within:
²Standard dimension = less than 0.05 mm (0.002
inch.)
²Service Limit = 0.2 mm (0.008 inch.)
²Grinding Limit = Maximum of 0.2 mm (0.008
inch.) is permitted.
CAUTION: 0.20 mm (0.008 in.) MAX is a combined
total dimension of the stock removal limit from cyl-
inder head and block top surface (Deck) together.
INSTALLATION - CYLINDER HEAD
(1) Clean all sealing surfaces of engine block and
cylinder heads. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
(2) Position new gasket(s) on engine block (Fig.
18). The left bank gasket is identified with the ªLº
stamped in the exposed area of the gasket located at
front of engine (shown in (Fig. 18)). The right bank
gasket is identified with a ªRº stamped in the
exposed area of the gasket also, but is located at the
rear of the engine.
(3)The cylinder head bolts are torqued using
the torque yield method, they should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts must be replaced(Fig. 19).
(4) Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.(5) Tighten the cylinder head bolts 1±8 in the
sequence shown in (Fig. 20). Using the 4 step torque
turn method, tighten according to the following val-
ues:
²Step 1: Bolts1±8to61N´m(45ft.lbs.)
²Step 2: Bolts1±8to88N´m(65ft.lbs.)
²Step 3: Bolts1±8(again) to 88 N´m (65 ft. lbs.)
²Step 4: Bolts1±8turn an additional 1/4 Turn.
(Do not use a torque wrench for this step.)
NOTE: Bolt torque after 1/4 turn should be over 122
N´m (90 ft. lbs.). If not, replace the bolt.
(6) Inspect push rods and replace worn or bent
rods.
(7) Install the push rods.
(8) Install the rocker arm and shaft assemblies.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - INSTALLATION)
Fig. 17 Checking Cylinder Head FlatnessÐTypical
Fig. 18 Head Gasket Installation
1 - CYLINDER HEAD GASKET
2 - LOCATION IDENTIFICATION (L = LEFT BANK, R = RIGHT
BANK)
Fig. 19 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
9 - 96 ENGINE 3.3/3.8LRS
CYLINDER HEAD (Continued)
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INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Inspect seal on the cover bolt for wear or dam-
age (Fig. 24). Replace bolt assembly as necessary.
NOTE: The cylinder head cover bolts contain a
torque limiter sleeve and a seal (Fig. 24). The seal
and torque sleeve is replaced with the bolt.
(3) Assemble gasket to cylinder cover by inserting
the bolt assemblies through each bolt hole on the
cover and gasket (Fig. 24).
(4) Install cylinder head cover and bolts (Fig. 25).
(5) Tighten cylinder head cover bolts to 12 N´m
(105 in. lbs.) (Fig. 25).
(6) Connect PCV hose to cylinder head cover.
(7) Connect power steering pump supply hose sup-
port clip to cylinder head cover (Fig. 22).
(8) Connect spark plug wires to spark plugs.
(9) Install wiper module. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(10) Connect negative cable to battery.
CYLINDER HEAD COVER -
LEFT
REMOVAL
(1) Disconnect spark plug wires from spark plugs.
(2) Disconnect crankcase vent hose from cylinder
head cover.
(3) Remove cylinder head cover bolts.
(4) Remove cylinder head cover and gasket.
Fig. 23 PCV Hose
1 - HOSE - PCV
2 - P C V VA LV E
Fig. 24 CYLINDER HEAD COVER GASKET
1 - CYLINDER HEAD COVER
2 - BOLT
3 - SEAL (SERVICED WITH BOLT)
4 - GASKET
Fig. 25 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - BOLT
9 - 98 ENGINE 3.3/3.8LRS
CYLINDER HEAD COVER - RIGHT (Continued)
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(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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TIMING BELT/CHAIN AND SPROCKETS -
REMOVAL)
(3) Remove the hydraulic lifters. (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - REMOVAL). Identify each tappet
for reinstallation in original location.
(4) Remove camshaft thrust plate (Fig. 45).
(5) Install a long bolt into front of camshaft to
facilitate removal of the camshaft.
(6) Remove the camshaft (Fig. 45), being careful
not to damage cam bearings with the cam lobes.
NOTE: The camshaft bearings are serviced with the
engine block.
INSPECTION
(1) Check the cam lobes and bearing surfaces for
abnormal wear and damage (Fig. 47). Replace cam-
shaft as required.
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the lifters.
(2) Measure the lobe actual wear (unworn area -
wear zone = actual wear) (Fig. 47) and replace cam-
shaft if out of limit. Standard value is 0.0254 mm
(0.001 in.), wearlimitis 0.254 mm (0.010 in.).
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals with engine oil.
(2) Install a long bolt into the camshaft to assist in
the installation of the camshaft.
(3) Carefully install the camshaft in engine block.
(4) Install camshaft thrust plate and bolts (Fig.
45). Tighten to 12 N´m (105 in. lbs.) torque.
(5) Measure camshaft end play. (Refer to 9 -
ENGINE - SPECIFICATIONS) If not within specifi-
cations, replace thrust plate.
(6) Install the timing chain and sprockets. (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT/
CHAIN AND SPROCKETS - INSTALLATION)
NOTE: When camshaft is replaced, all of the
hydraulic lifters must be replaced also.
(7) Install the hydraulic lifters (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - INSTALLATION). Each lifter
Fig. 45 CAMSHAFT AND BEARINGS
1 - CAMSHAFT
2 - THRUST PLATE
3 - BOLT
4 - CAMSHAFT BEARINGS (SERVICED WITH BLOCK)
Fig. 46 CAMSHAFT IDENTIFICATION
1 - CAMSHAFT - 3.3L ENGINE
2 - CAST-IN RING
3 - CAMSHAFT - 3.8L ENGINE
4 - MACHINED CAST-IN RING
Fig. 47 Checking Camshaft for Wear (Typical)
1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE
9 - 108 ENGINE 3.3/3.8LRS
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
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reused must be installed in the same position from
which it was removed.
(8) Install the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(9) Install the cylinder heads. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION)
(10) Install the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(11) Install the lower and upper intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - INSTALLATION)
(12) Install the engine assembly. (Refer to 9 -
ENGINE - INSTALLATION)
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - MEASURING
CONNECTING ROD BEARING CLEARANCE
The bearing caps are not interchangeable and
should be marked at removal to ensure correct
assembly. The bearing shells must be installed with
the tangs inserted into the machined grooves in the
rods and caps. Install cap with the tangs on the same
side as the rod. Fit all rods on one bank until com-
plete. Connecting rod bearings are available in the
standard size and the following undersizes: 0.025
mm (0.001 in.) and 0.250 mm (0.010 in.).
CAUTION: Install the bearings in pairs. Do not use a
new bearing half with an old bearing half. Do not
file the rods or bearing caps.
Measure connecting rod journal for taper and out-
of-round. (Refer to 9 - ENGINE/ENGINE BLOCK/
CRANKSHAFT - INSPECTION)
The connecting rod bearing clearances can be
determined by use of Plastigage or the equivalent.
The following is the recommended procedure for the
use of Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(3) Place a piece of Plastigage across the entire
width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 in.) off center and away from
the oil hole. In addition, suspect areas can be
checked by placing Plastigage in that area.
(4) Assemble the rod cap with Plastigage in place.
Tighten the rod cap to the specified torque.Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.(5) Remove the bearing cap and compare the
width of the flattened Plastigage with the scale pro-
vided on the package (Fig. 48). Locate the band clos-
est to the same width. This band indicates the
amount of oil clearance. Differences in readings
between the ends indicate the amount of taper
present. Record all readings taken. Refer to Engine
Specifications (Refer to 9 - ENGINE - SPECIFICA-
TIONS).Plastigage generally is accompanied by
two scales. One scale is in inches, the other is a
metric scale. If the bearing clearance exceeds
wear limit specification, replace the bearing.
CRANKSHAFT
DESCRIPTION - 3.3L
The nodular iron crankshaft is supported by four
main bearings, with number two position the thrust
bearing (Fig. 49). Crankshaft end sealing is provided
by front and rear rubber seals.
DESCRIPTION - 3.8L
The nodular iron crankshaft is supported by four
main bearings, with number two position providing
thrust bearing location (Fig. 50). Each main bearing
cap has two vertical retaining bolts. The two center
main caps have horizontal bolts to add increased
rigidity to the lower engine block (Fig. 50). Crank-
shaft end sealing is provided by front and rear rub-
ber seals.
Fig. 48 Measuring Connecting Rod Bearing
Clearance
RSENGINE 3.3/3.8L9 - 109
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
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(2) Alternative Method:
²Support the weight of the crankshaft with a jack
under the counterweight adjacent to the bearing
being checked.
(3) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(4) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 58). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(5) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 59) with the scale
provided on the package. Locate the band closest to
the same width. This band shows the amount of
clearance in thousandths. Differences in readings
between the ends indicate the amount of taper
present. Record all readings taken. (Refer to 9 -
ENGINE - SPECIFICATIONS)Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.PLASTIGAGE METHODÐENGINE OUT-OF-VEHICLE
(1) With engine in the inverted position (crank-
shaft up) and mounted on a repair stand, remove
main journal cap.
(2) Remove oil from journal and bearing shell.
(3) Cut Plastigage to same length as width of the
bearing and place it in parallel with the journal axis
(Fig. 58).
(4) Carefully install the main bearing cap and
tighten the bolts to specified torque.
CAUTION: Do not rotate crankshaft or the Plasti-
gage will be smeared.
(5) Carefully remove the bearing cap and measure
the width of the Plastigage at the widest part using
the scale on the Plastigage package (Fig. 59). Refer
to Engine Specifications for proper clearances (Refer
to 9 - ENGINE - SPECIFICATIONS). If the clearance
exceeds the specified limits, replace the main bear-
ing(s) with the appropriate size, and if necessary,
have the crankshaft machined to next undersize.
REMOVAL - CRANKSHAFT MAIN BEARINGS
(1) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(2) Identify main bearing caps before removal.
(3) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Special Main Bear-
ing Tool C-3059 (Fig. 60) into the oil hole of crank-
shaft.
(4) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig. 58 Plastigage Placed in Lower
1 - PLASTIGAGE
Fig. 59 Clearance Measurement
Fig. 60 Upper Main Bearing Removing/Installing
With Special Tool C-3059
1 - SPECIAL TOOL C-3059
2 - BEARING
3 - SPECIAL TOOL C-3059
4 - BEARING
9 - 114 ENGINE 3.3/3.8LRS
CRANKSHAFT MAIN BEARINGS (Continued)
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