2001 DODGE TOWN AND COUNTRY torque

FUEL RAIL
REMOVAL - 2.4L
(1) Perform fuel system pressure release procedure
before servicing or starting repairs.Refer to
Fuel System Pressure Release Procedure in this sec-
tion.
(2) Disconnect negative cable from battery.
(3) Disconnect the wiring connectors for fuel injec-
tors harness (Fig. 13).
(4) Remove wiring harness from brackets.
(5) Disconnect the connectors from the fuel injec-
tors.
(6) Remove harness from vehicle.
(7) Remove fuel hose quick connect fitting from the
chassis tube.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Place a
shop towel under the connections to absorb any fuel
spilled from the fitting.
WARNING: WRAP A SHOP TOWEL AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(8) Remove fuel rail attaching bolts.
(9) Remove fuel rail. Be careful not to damage the
injector O-rings upon removal from their ports.
REMOVAL - 3.3/3.8L
(1) Perform fuel system pressure release procedure
before servicing or starting repairs.Refer to
Fuel System Pressure Release Procedure in this sec-
tion.
(2) Disconnect negative cable from battery.
(3) Remove upper intake manifold, refer to the
Engine/Manifolds/Upper Intake for more informa-
tion..
(4) Cover intake manifold with suitable cover
when servicing.(5) Remove the fuel hose quick connect fitting from
the chassis tube.Refer to Fuel Hoses, Clamps
and Quick Connect Fittings in this Section.
WARNING: WRAP A SHOP TOWEL AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(6) Remove the fuel rail attaching bolts (Fig. 14).
(7) Remove fuel rail. Be careful not to damage the
injector O-rings upon removal from their ports.
INSTALLATION - 2.4L
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque.
(5) Connect the connectors to the fuel injectors.
(6) Install wiring harness to brackets.
(7) Connect the wiring connectors to fuel injectors
harness (Fig. 13).
(8) Connect negative battery cable.
(9) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
INSTALLATION - 3.3/3.8L
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
Fig. 13 FUEL RAIL AND INJECTORS 2.4L
1 - Fuel Injectors
2 - Fuel Rail
Fig. 14 FUEL INJECTORS 3.3/3.8L
1 - FUEL INJECTORS
RSFUEL DELIVERY14-9
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(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque.
(5) Remove covering on lower intake manifold and
clean surface.
(6) Install the Upper Intake Manifold, refer to
Engine/Manifolds/Upper Intake for more information.
(7) Install fuel hose quick connector fitting to chas-
sis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Push the
fitting onto the chassis tube until it clicks into place.
Pull on the fitting to ensure complete insertion.
(8) Connect negative cable to battery.
(9) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module. The tank is made
from High density Polyethylene (HDPE) material.If
equipped with ORVR (Onboard Refueling Vapor
Recovery) it has been added to the fuel tank to con-
trol refueling vapor emissions.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.
All models are equipped with either one or two
rollover valves mounted into the top of the fuel tank
(or pump module).
An evaporation control system is connected to the
rollover valve(s)/control valves(Refer to 25 - EMIS-
SIONS CONTROL/EVAPORATIVE EMISSIONS/
ORVR - OPERATION) to reduce emissions of fuel
vapors into the atmosphere. When fuel evaporates
from the fuel tank, vapors pass through vent hoses or
tubes to a charcoal canister where they are tempo-
rarily held. When the engine is running, the vapors
are drawn into the intake manifold. In addition, fuel
vapors produced during vehicle refueling are allowed
to pass through the vent hoses/tubes to the charcoal
canister(s) for temporary storage (prior to being
drawn into the intake manifold). All models areequipped with a self-diagnosing system using a Leak
Detection Pump (LDP). Refer to the Emission Control
System for additional information.
INLET CHECK VALVE
All vehicles have an inlet check valve on the inside
of the fuel tank at the filler inlet
The valve prevents fuel from splashing back on
customer during vehicle refueling. The valve is a
non-serviceable item.
REMOVAL
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure.
(2) Disconnect negative cable from battery.
(3) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(4) Drain fuel tank dry into holding tank or a
properly labeledGASOLINEsafety container.
(5) Raise vehicle on hoist and support.
(6) Use a transmission jack to support fuel tank.
Remove bolts from fuel tank straps.
(7) Lower tank slightly.
Fig. 15 Fuel Tank
1 - ROLLOVER VALVE
2 - FUEL FILLER INLET
3 - ROLLOVER VALVE
4 - GROUND STRAP
5 - FUEL FILTER
6 - FUEL PUMP MODULE
14 - 10 FUEL DELIVERYRS
FUEL RAIL (Continued)
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(8) Disconnect the fuel filler vent tube. Squeeze
tabs and pull apart (Fig. 16).
(9) Disconnect the fuel fill hose at the fuel tank
filler metal tubeNOT AT THE FUEL TANK(Fig.
16).
(10) Disconnect fuel line and vapor line at the
front of the fuel tank.
The fuel pump module electrical connector
has a retainer that locks it in place.
(11) Slide fuel pump module electrical connector
lock to unlock (Fig. 17).
(12) Push down on connector retainer (Fig. 18) and
pull connector off module.
(13) Lower tank from vehicle. Remove fuel filler
vent tube from frame (Fig. 19).
INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect rollover valve hose. Connect fuel filler tube vent
hose and tighten clamp.
(2) Raise tank into position and carefully work
filler metal tube into the rubber hose on fuel tank. A
light coating of clean engine oil on the tube end may
be used to aid assembly.
(3) Feed filler vent line thru frame rail. Careful
not to cross lines.
(4) Tighten strap bolts to 54 N´m (40 ft. lbs.)
torque. Tighten T strap bolt to 28.2 N´m (250 in.
lbs.). Remove transmission jack.(5) Tighten filler hose clamp to 3.3 N´m (30 in.
lbs.).
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(6) Connect fuel pump/module electrical connector.
Place retainer in locked position.
(7) Lubricate the fuel supply line with clean 30
weight engine oil, install the quick connect fuel fit-
ting. Refer to Tube/Fitting Assembly in the Fuel
Delivery section of this section.
(8) Attach filler vent line to filler tube. Pull on
connector to make sure of connection.
Fig. 16 FUEL FILLER AND VENT TUBE
1 - Filler Tube
2 - Vent Tube
Fig. 17 Fuel Line Retainers and Pump Connector
Lock
1 - PUSH
2 - CONNECTOR LOCK
3 - QUICK CONNECT RETAINERS
Fig. 18 Pump Module Connector Retainer and Lock
1 - PUSH DOWN ON RETAINER
2 - CONNECTOR LOCK
RSFUEL DELIVERY14-11
FUEL TANK (Continued)
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SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
MAP SENSOR PLASTIC
MANIFOLD1.7 15
MAP SENSOR
ALUMINUM MANIFOLD3.3 30
POWER STEERING
RESERVOIR PLASTIC
MANIFOLD5.7 50
POWER STEERING
RESERVOIR ALUMINUM
MANIFOLD11.9 105
THROTTLE CABLE
BRACKET PLASTIC
MANIFOLD5.7 50
THROTTLE CABLE
BRACKET ALUMINUM
MANIFOLD11.9 105
EGR TUBE PLASTIC
MANIFOLD5.7 50
EGR TUBE ALUMINUM
MANIFOLD11.9 105
THROTTLE BODY BOLTS
2.4L28 20.65 250650
THROTTLE BODY BOLTS
3.3/3.8/3.5L11.8 8.7 105620
O2 Sensors 27 20
The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and
installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600
rpms) to avoid melting the parent material. There are service repair screws avialable for repair. They require a
higher torque than the original screws..
RSFUEL INJECTION14-21
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ACCELERATOR PEDAL
REMOVAL
(1) Hold the throttle body throttle lever in the
wide open position. Remove the throttle cable from
the throttle body cam.
(2) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft.
(3) Remove nuts from accelerator pedal attaching
studs. Remove assembly from vehicle.
INSTALLATION
(1) Position accelerator pedal assembly on dash
panel. Install retaining nuts. Tighten retaining nuts
to 12 N´m (105 in. lbs.) torque.
(2) From inside the vehicle, hold up the pedal and
install the throttle cable and cable retainer in the
upper end of the pedal shaft.
(3) From the engine compartment, hold the throt-
tle body lever in the wide open position and install
the throttle cable.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
The 2.4L crankshaft sensor is located on the rear
of the engine near the accessory drive belt (Fig. 1).
The 3.3/3.8L crankshaft sensor is located on the rear
of the transmission housing, above the differential
housing (Fig. 2). The bottom of the sensor is posi-
tioned next to the drive plate.
OPERATION
The crankshaft position sensor detects slots cut
into the transmission driveplate extension (Fig. 3).
There are 3 sets of slots. Each set contains 4 slots,
for a total of 12 slots (Fig. 4). Basic timing is set by
the position of the last slot in each group. Once the
Powertrain Control Module (PCM) senses the last
slot, it determines crankshaft position (which piston
will next be at TDC) from the camshaft position sen-
sor input. The 4 pulses generated by the crankshaft
position sensor represent the 69É, 49É, 29É, and 9É
BTDC marks. It may take the PCM one engine rev-
olution to determine crankshaft position.
The PCM uses crankshaft position reference to
determine injector sequence, ignition timing and the
presence of misfire. Once the PCM determines crank-
shaft position, it begins energizing the injectors in
sequence.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) Disconnect the electrical connector (Fig. 5).
(4) Remove crankshaft sensor bolt.
(5) Remove the crankshaft sensor.
REMOVAL - 3.3/3.8L
(1) Remove battery, refer to the Battery section for
more information.
(2) Remove the battery tray, refer to the Battery
section for more information.
Fig. 1 CRANKSHAFT SENSOR 2.4L
1 - CRANKSHAFT POSITION SENSOR
Fig. 2 CRANKSHAFT SENSOR 3.3/3.8L
RSFUEL INJECTION14-23
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(3) Disconnect the speed control vacuum harness
from servo.
(4) Remove the speed control servo and bracket
and reposition. Disconnect the electrical connector.
(5) Disconnect the electrical connector from crank-
shaft sensor.
(6) Remove the mounting bolt.
(7) Remove sensor.
INSTALLATION - 2.4L
(1) Install the crankshaft sensor.
(2) Install crankshaft sensor bolt and tighten.
(3) Connect the electrical connector (Fig. 5).
(4) Lower vehicle.
(5) Connect the negative battery cable.
INSTALLATION - 3.3/3.8L
(1) Install the crankshaft sensor.
(2) Install the mounting bolt and tighten.
(3) Connect the electrical connector to crankshaft
sensor. Make sure locking tab is in position.
(4) Connect the electrical connector to the speed
control servo.
(5) Install the speed control servo and bracket.
(6) Connect the speed control vacuum harness to
servo.
(7) Install the battery tray, refer to the Battery
section for more information.
(8) Install battery, refer to the Battery section for
more information.
ENGINE SPEED SENSOR
DESCRIPTION
The PCM receives a signal from the TCM and the
transaxle output speed sensor over the bus communi-
cation line.
OPERATION
The Transmission Control Module (TCM) supplies
the road speed and distance traveled inputs to the
PCM. From these inputs and the throttle position
sensor input, the PCM determines when a decelera-
tion condition occurs.
Fig. 3 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
Fig. 4 Timing Slots
1 - TORQUE CONVERTER DRIVE PLATE
2 - SLOTS
Fig. 5 CRANKSHAFT SENSOR 2.4L
1 - CRANKSHAFT POSITION SENSOR
14 - 24 FUEL INJECTIONRS
CRANKSHAFT POSITION SENSOR (Continued)
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²TPS
²MAP Sensor
REMOVAL
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. Never use lubricants on O-rings or
seals, damage may result. If assembly of component
is difficult, use water to aid assembly. Use care when
removing hoses to prevent damage to hose or hose
nipple.
(1) Disconnect negative cable from battery.
(2) Remove electrical connector from idle air con-
trol motor.
(3) Remove idle air control motor mounting screws.
(4) Remove motor from throttle body. Ensure the
O-rings is removed with the motor.
INSTALLATION
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. Never use lubricants on O-rings or
seals, damage may result. If assembly of component
is difficult,a light coat of engine oil may be
applied to the O-RINGS ONLY (Fig. 13)to aid
assembly. Use care when removing hoses to prevent
damage to hose or hose nipple.
(1) The new idle air control motor has a new
O-ring installed on it. For 2.4L only, if pintle mea-
sures more than 1 inch (25 mm) it must be retracted.
Use the DRB Idle Air Control Motor Open/Close Test
to retract the pintle (battery must be connected.)
(2) Carefully place idle air control motor into
throttle body.
(3) Install mounting screw(s). Tighten screws to 2
N´m (17 in. lbs.) torque.
(4) Connect electrical connector to idle air control
motor.
(5) Connect negative cable to battery.
INLET AIR TEMPERATURE
SENSOR
DESCRIPTION
The IAT Sensor is a Negative Temperature Coeffi-
cient (NTC) Sensor that provides information to the
PCM regarding the temperature of the air entering
the intake manifold (Fig. 14).
OPERATION
Inlet/Intake Air Temperature
The inlet air temperature sensor replaces the
intake air temperature sensor and the battery tem-
perature sensor. The PCM uses the information from
the inlet air temperature sensor to determine values
to use as an intake air temperature sensor and a bat-
tery temperature sensor.
The Intake Air Temperature (IAT) sensor value is
used by the PCM to determine air density.
The PCM uses this information to calculate:
²Injector pulse width
²Adjustment of ignition timing (to prevent spark
knock at high intake air temperatures)
Battery Temperature
The inlet air temperature sensor replaces the
intake air temperature sensor and the battery tem-
perature sensor. The PCM uses the information from
the inlet air temperature sensor to determine values
for the PCM to use as an intake air temperature sen-
sor and a battery temperature sensor.
The battery temperature information along with
data from monitored line voltage (B+), is used by the
Fig. 13 O-RINGS
1 - O-rings
Fig. 14 3.3/3.8L IAT SENSOR
1 - INLET AIR TEMPERATURE SENSOR
14 - 28 FUEL INJECTIONRS
IDLE AIR CONTROL MOTOR (Continued)
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OPERATION
Filtered air from the air cleaner enters the intake
manifold through the throttle body. The throttle body
contains an air control passage controlled by an Idle
Air Control (IAC) motor. The air control passage is
used to supply air for idle conditions. A throttle valve
(plate) is used to supply air for above idle conditions.
Certain sensors are attached to the throttle body.
The accelerator pedal cable, speed control cable and
transmission control cable (when equipped) are con-
nected to the throttle body linkage arm.
A (factory adjusted) set screw is used to mechani-
cally limit the position of the throttle body throttle
plate.Never attempt to adjust the engine idle
speed using this screw.All idle speed functions are
controlled by the PCM.
REMOVAL
(1) Disconnect negative cable from battery cable.
(2) Remove air inlet to throttle body hose clamp.
(3) Remove throttle and the speed control (if
equipped) cables from lever and bracket.
(4) Disconnect electrical connectors from the idle
air control motor and throttle position sensor (TPS)
(Fig. 23) or (Fig. 24).
(5) Remove throttle body to intake manifold
attaching bolts.
(6) Remove throttle body and gasket.
INSTALLATION
(1) Install a new gasket.
(2) Install throttle body.
(3) Tighten throttle body mounting bolts. The 2.4L
to 28.2 N´m (250650 in. lbs.) torque, The 3.3/3.8L to
11.6 N´m (105620 in. lbs.) torque.
(4) Connect electrical connectors to the idle air
control motor and throttle position sensor (TPS) (Fig.
23) or (Fig. 24).
(5) Install air inlet to throttle body hose clamp and
tighten.
(6) Connect negative cable to battery cable.
THROTTLE CONTROL CABLE
REMOVAL
(1) Working from the engine compartment, hold
the throttle body throttle lever in the wide open posi-
tion.
(2) Remove the throttle cable from the throttle
body cam.
(3) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft.
(4) Remove retainer clip from throttle cable and
grommet at dash panel.(5) From the engine compartment, pull the throttle
cable out of the dash panel grommet. The grommet
should remain in the dash panel.
(6) Remove the throttle cable from throttle bracket
by carefully compressing both retaining ears simulta-
neously. Then gently pull the throttle cable from
throttle bracket.
INSTALLATION
(1) From the engine compartment, push the hous-
ing end fitting into the dash panel grommet.
(2) Install the cable housing (throttle body end)
into the cable mounting bracket on the engine.
(3) From inside the vehicle, hold up the pedal and
install throttle cable and cable retainer in the upper
end of the pedal shaft.
(4) At the dash panel, install the cable retainer
clip between the end of the throttle cable fitting and
grommet
(5) From the engine compartment, rotate the
throttle lever wide open and install the throttle
cable.
THROTTLE POSITION SENSOR
DESCRIPTION
The throttle position sensor mounts to the side of
the throttle body (Fig. 25) or (Fig. 26).The sensor
connects to the throttle blade shaft. The TPS is a
variable resistor that provides the Powertrain Con-
trol Module (PCM) with an input signal (voltage).
Fig. 25 Throttle Position SensorÐ2.4L Engine
1 - IAC MOTOR
2 - TP SENSOR
3 - IAT SENSOR
14 - 34 FUEL INJECTIONRS
THROTTLE BODY (Continued)
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