2001 DODGE TOWN AND COUNTRY Engine

CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Remove transaxle. Refer to Group 21, Tran-
saxle for procedure.
(2) Remove flex plate.
(3) Insert a 3/16 flat bladed screwdriver between
the dust lip and the metal case of the crankshaft
seal. Angle the screwdriver (Fig. 62) through the dust
lip against metal case of the seal. Pry out seal.
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
Fig. 60 Crankshaft Front Oil Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 61 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
Fig. 62 Rear Crankshaft Oil SealÐRemoval
1 - REAR CRANKSHAFT SEAL
2 - ENGINE BLOCK
3 - ENGINE BLOCK
4 - REAR CRANKSHAFT SEAL METAL CASE
5 - PRY IN THIS DIRECTION
6 - CRANKSHAFT
7 - SCREWDRIVER
8 - REAR CRANKSHAFT SEAL DUST LIP
9 - SCREWDRIVER
RSENGINE 2.4L9-41
CRANKSHAFT OIL SEAL - FRONT (Continued)
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NOTE: When installing seal, no lube on seal is
needed.
(1) Place Special Tool 6926-1 Seal Guide on crank-
shaft (Fig. 63).
(2) Position seal over guide tool (Fig. 63). Guide
tool should remain on crankshaft during installation
of seal. Ensure that the lip of the seal is facing
towards the crankcase during installation.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Drive the seal into the block using Special Tool
6926-2 and handle C-4171 (Fig. 64) until the tool bot-
toms out against the block (Fig. 65).
(4) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten bolts to 95 N´m
(70 ft. lbs.).
(5) Install transaxle. Refer to Group 21, Transaxle
for procedure.
PISTON & CONNECTING ROD
DESCRIPTION
The pistons are made of a cast aluminum alloy.
The pistons have pressed-in pins attached to forged
powdered metal connecting rods. The pistons pin isoffset 1 mm (0.0394 in.) towards the thrust side of
the piston. The connecting rods are a cracked cap
design and are not repairable. Hex head cap screws
are used to provide alignment and durability in the
assembly. The pistons and connecting rods are ser-
viced as an assembly.
OPERATION
The piston and connecting rod is the link between
the combustion force to the crankshaft.
REMOVAL
NOTE: Cylinder Head must be removed before Pis-
tons and Rods. Refer to Cylinder Head Removal in
this section.
(1) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block.Be sure to keep tops of pistons
covered during this operation. Mark piston with
matching cylinder number (Fig. 66).
(2) Remove oil pan. Scribe the cylinder number on
the side of the rod and cap (Fig. 67) for identification.
(3) Pistons have a directional stamping in the
front half of the piston facing towards thefrontof
engine.
Fig. 63 Rear Crankshaft Seal and Special Tool
6926-1
1 - SPECIAL TOOL 6926±1 PILOT
2 - SEAL
Fig. 64 Crankshaft Seal and Special Tools 6926-2 &
C-4171
1 - SPECIAL TOOL 6926±1 PILOT
2 - SEAL
3 - SPECIAL TOOL 6926±2 INSTALLER
4 - SPECIAL TOOL C-4171
9 - 42 ENGINE 2.4LRS
CRANKSHAFT OIL SEAL - REAR (Continued)
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(4) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(5) Remove Balance Shaft Assembly. Refer to Bal-
ance Shaft Removal in this section.
(6) Remove connecting rod cap bolts. Push each
piston and rod assembly out of cylinder bore.NOTE: Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mat-
ing rod.
(8) Piston and Rods are serviced as an assembly.
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.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 68). As viewed
from top.
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 69).Be sure position of rings does not
change during this operation.
(4) The directional stamp on the piston should face
toward the front of the engine (Fig. 66).
Fig. 65 Rear Crankshaft SealÐInstallation
1 - SPECIAL TOOL 6926±2 INSTALLER
Fig. 66 Piston Markings
1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
Fig. 67 Identify Connecting Rod to Cylinder
Fig. 68 Piston Ring End Gap Position
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
RSENGINE 2.4L9-43
PISTON & CONNECTING ROD (Continued)
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(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston assembly into cylinder bore and guide
rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
NOTE: The connecting rod cap bolts should not be
reused.
(7) Before installing theNEWbolts the threads
should be coated with clean engine oil.
(8) Install each bolt finger tight than alternately
torque each bolt to assemble the cap properly.
CAUTION: Do not use a torque wrench for second
part of last step.
(9) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn).
(10) Using a feeler gauge, check connecting rod
side clearance (Fig. 70).
PISTON RINGS
PISTON RINGÐFITTING
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 inch) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 71).
Refer to Engine Specifications.
(2) Check piston ring to groove side clearance (Fig.
72). Refer to Engine Specifications.
Fig. 69 PistonÐInstallation
Fig. 70 Checking Connecting Rod Side Clearance
Fig. 71 Piston Ring Gap
1 - FEELER GAUGE
Fig. 72 Piston Ring Side Clearance
1 - FEELER GAUGE
9 - 44 ENGINE 2.4LRS
PISTON & CONNECTING ROD (Continued)
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PISTON RINGSÐINSTALLATION
(1) Install rings with manufacturers I.D. mark fac-
ing up, to the top of the piston (Fig. 73).
CAUTION: Install piston rings in the following
order:
²Oil ring expander.
²Upper oil ring side rail.
²Lower oil ring side rail.
²No. 2 Intermediate piston ring.
²No. 1 Upper piston ring.
(2) Install the side rail by placing one end
between the piston ring groove and the expander.
Hold end firmly and press down the portion to be
installed until side rail is in position.Do not use a
piston ring expander(Fig. 74).
(3) Install upper side rail first and then the lower
side rail.
(4) Install No. 2 piston ring and then No. 1 piston
ring.
(5) Position piston ring end gaps as shown in (Fig.
75).
(6) Position oil ring expander gap at least 45É
from the side rail gaps butnoton the piston pin cen-
ter or on the thrust direction. Staggering ring gap is
important for oil control.
Fig. 73 Piston Ring Installation
1 - NO. 1 PISTON RING
2 - NO. 2 PISTON RING
3 - SIDE RAIL
4 - OIL RING
5 - SPACER EXPANDER
Fig. 74 Installing Side Rail
1 - SIDE RAIL END
Fig. 75 Piston
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
RSENGINE 2.4L9-45
PISTON RINGS (Continued)
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VIBRATION DAMPER
REMOVAL
(1) Remove accesory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(2) Remove crankshaft damper bolt.
(3) Remove damper using Special Tool 3-Jaw
Puller 1026 and Insert 6827±A (Fig. 76).
INSTALLATION
(1) Install crankshaft vibration damper using M12
1.75 x 150 mm bolt, washer, thrust bearing and nut
from Special Tool 6792 (Fig. 77).
(2) Install crankshaft vibration damper bolt and
tighten to 142 N´m (105 ft. lbs.).
(3) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
STRUCTURAL COLLAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove engine front mount bracket and front
insulator mount. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - REMOVAL)
(3) Remove structural collar attaching bolts (Fig.
78).
(4) Remove collar.
INSTALLATION
CAUTION: Torque procedure for the structural collar
must be followed or damage could occur to oil pan
and collar.(1) Perform the following steps for installing struc-
tural collar. Refer to (Fig. 78):
²Step 1: Position collar between transaxle and oil
pan. Install collar to transaxle bolt,hand start
only.
²Step 2: Install collar to oil pan bolts,hand snug
only.
Fig. 76 Crankshaft Vibration Damper - Removal
1 - SPECIAL TOOL 1026 3-JAW PULLER
2 - SPECIAL TOOL 6827±A INSERT
Fig. 77 Crankshaft Vibration Damper - Installation
1 - M12±1.753150 MM BOLT, WASHER AND THRUST
BEARING FROM SPECIAL TOOL 6792
Fig. 78 Structural Collar
1 - BOLT - COLLAR TO OIL PAN
2 - BOLT - COLLAR TO TRANSAXLE
3 - STRUCTURAL COLLAR
4 - OIL PAN
9 - 46 ENGINE 2.4LRS
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²Step 3: Final torque collar to transaxle bolts to
101 N´m (75 ft. lbs.)
²Step 4: Final torque collar to oil pan bolts to 54
N´m (40 ft. lbs.).
(2) Install engine front mount bracket and insula-
tor. (Refer to 9 - ENGINE/ENGINE MOUNTING/
FRONT MOUNT - INSTALLATION)
(3) Lower vehicle.
ENGINE MOUNTING
DESCRIPTION
The engine mounting system consist of four
mounts; right and a left side support the powertrain,
and a front and a rear mount control powertrain
torque. The right side mount is a hydro-type (Fig.
79), all others are of molded rubber material.
FRONT MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the front engine mount through bolt
from the insulator (Fig. 80).
(3) Remove the engine front mount bolts and
remove the insulator assembly (Fig. 80).(4) Remove the front mounting bracket from
engine, if necessary (Fig. 80).
INSTALLATION
(1) Install the front mount bracket to engine, if
removed (Fig. 80).
(2) Install the insulator mount assembly (Fig. 80).
(3) Install the front engine mount through bolt to
the insulator (Fig. 80).
(4) Lower the vehicle.
LEFT MOUNT
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the left front wheel.
(3) Remove the left mount through bolt access
cover.
(4) Support the transaxle with a suitable jack.
(5) Remove the engine front mount through bolt to
allow left mount removal clearance (Fig. 90).
(6) Remove the left mount through frame rail bolt
(Fig. 81).
(7) Lower transaxle for access to horizontal bolts.
Fig. 79 Engine Hydro-type Mount - Right Side
1 - BOLT
2 - BOLT
3 - FRAME RAIL
4 - RIGHT MOUNT - 2.4L ENGINE
5 - RIGHT MOUNT - 3.3/3.8L ENGINE
Fig. 80 Front Mount and Bracket
1 - BRACKET - FRONT MOUNT
2 - NUT - 68 N´m (50 ft. lbs.)
3 - BOLT - 54 N´m (40 ft. lbs.)
4 - MOUNT - FRONT INSULATOR
5 - BOLT - 68 N´m (50 ft. lbs.)
6 - BOLT - 68 N´m (50 ft. lbs.)
7 - FRONT CROSSMEMBER
RSENGINE 2.4L9-47
STRUCTURAL COLLAR (Continued)
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(8) Remove the horizontal bolts from the mount to
the transaxle (Fig. 82) or (Fig. 83).
NOTE: To remove mount, additional lowering of
transaxle may be required.
(9) Remove left mount.
INSTALLATION
(1) Install left mount on transaxle (Fig. 82) or (Fig.
83).
(2) Raise transaxle with jack until left mount is in
position.
(3) Install left mount through bolt (Fig. 81).
(4) Install left mount through bolt access cover.
(5) Install front mount through bolt (Fig. 80).
(6) Install left front wheel.
(7) Lower vehicle.
REAR MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the rear mount heat shield (Fig. 84).
(3) Remove the through bolt from the mount and
rear mount bracket (Fig. 85).
(4) Remove the mount bolts (Fig. 85).
(5) Remove the rear mount (Fig. 85).
(6) For rear mount bracket removal, remove the
bolts attaching bracket to transaxle (Fig. 86).
(7) Remove rear mount bracket.
INSTALLATION
(1) Install rear mount bracket, if removed (Fig.
86).
(2) Install the rear mount and bolts (Fig. 85).
Tighten bolts to 54 N´m (40 ft. lbs.).
(3) Install the mount through bolt to the mount
and bracket (Fig. 85). Tighten through bolt to 54 N´m
(40 ft. lbs.).
(4) Install the rear mount heat shield (Fig. 84).
Fig. 81 LEFT MOUNT TO BRACKET
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
Fig. 82 LEFT MOUNT - 31TH TRANSAXLE
1 - LEFT MOUNT ASEMBLY
2 - BOLT - 54 N´m (40 ft. lbs.)
3 - TRANSAXLE - 31TH
Fig. 83 LEFT MOUNT - 41TE TRANSAXLE
1 - LEFT MOUNT ASSEMBLY
2 - BOLT - 54 N´m (40 ft. lbs.)
3 - TRANSAXLE - 41TE
9 - 48 ENGINE 2.4LRS
LEFT MOUNT (Continued)
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