2001 DODGE TOWN AND COUNTRY air condition

CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake
vacuum booster.
(12) Remove vacuum seal located on the mounting
flange of the master cylinder. The vacuum seal is
removed from master cylinder bycarefullypulling it
off the rear of master cylinder.Do not attempt to
pry the seal off the master cylinder by inserting
a sharp tool between seal and master cylinder
casting.
INSTALLATION
CAUTION: Different types of master cylinders are
used on this vehicle depending on brake options. If
a new master cylinder is being installed, be sure it
is the correct master cylinder for the type of brake
system the vehicle is equipped with.
CAUTION: When replacing the master cylinder on a
vehicle, a NEW vacuum seal MUST be installed on
the master cylinder.
(1) Install a NEW vacuum seal on master cylinder
making sure seal fits squarely in groove of master
cylinder casting.
(2) Position master cylinder on studs of power
brake booster, aligning booster push rod with master
cylinder piston.
(3) Install the two master cylinder mounting nuts
(Fig. 2). Tighten both mounting nuts to a torque of
25 N´m (225 in. lbs.).
CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.
(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig. 2).
Brake tubes must be held securely when tightened to
control orientation of flex section. Tighten tube nuts
to a torque of 17 N´m (145 in. lbs.).
(5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig. 1).
(6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.(10) Fill master cylinder with clean, fresh Mopart
Brake Fluid or equivalent.
(11) Road test vehicle to ensure proper operation of
brakes.
PEDAL TORQUE SHAFT
REMOVAL
(1) Remove the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL)
(2) Remove the HVAC housing. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL)
(3) Remove the retaining clip at the torque shaft
end of the brake pedal-to-torque shaft link. Remove
the link from the torque shaft. Discard the retaining
clip. It is not to be reused. Replace with a new clip
when reassembled.
(4) Locate the booster input rod-to-brake pedal
torque shaft connection and remove the retaining clip
(Fig. 3). Discard the retaining clip. It is not to be
reused. Replace with a new clip when reassembled.
(5) Remove the four (4) brake booster retaining
nuts from inside the passenger compartment (Fig. 4).
(6) Remove the retaining nut from the brake
booster bracket located above the booster in the
engine compartment (Fig. 4).
(7) Remove the power brake booster bracket.
(8) Rotate the pedal torque shaft and remove it out
the left side of the vehicle.
Fig. 3 POWER BRAKE BOOSTER BRACKET
1 - BOOSTER BRACKET
2 - PEDAL TORQUE SHAFT
3 - RETAINING CLIP
4 - BOOSTER MOUNTING NUTS
RGBRAKES - BASE5a-3
MASTER CYLINDER - RHD (Continued)
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INSTALLATION
(1) Lubricate both ends of the torque shaft with
MS-4517 Lubricant or equivalent and install the
torque shaft from the left side reversing the removal
procedure.
(2) Install the brake booster bracket on the left
end of the shaft.
(3) Install the four brake booster retaining nuts
inside the passenger compartment. Tighten the
mounting nuts to a torque of 29 N´m (250 in. lbs.).
(4) Install the retaining nut for the brake booster
bracket in the engine compartment. Tighten the
mounting nuts to a torque of 29 N´m (250 in. lbs.).
(5) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal torque shaft pin where it con-
tacts the booster input rod. Also coat the surface of
the brake pedal torque shaft pin where it contacts
the brake pedal link.
CAUTION: When installing the power brake booster
input rod on the brake pedal torque shaft pin, do
not reuse the old retaining clip.(6) Install booster input rod on brake pedal torque
shaft pin and install a NEW retaining clip (Fig. 3).
CAUTION: When installing the brake pedal link on
the brake pedal torque shaft pin, do not reuse the
old retaining clip.
(7) Connect the brake pedal link to the torque
shaft. Install a NEW retaining clip at the torque
shaft end of the brake pedal-to-torque shaft link.
(8) Install the HVAC housing. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION)
(9) Install the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION)
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(10) Remove and replace the brake lamp switch
with a NEW switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION)
(11) Road test vehicle to ensure proper operation of
the brakes.POWER BRAKE BOOSTER -
RHD
REMOVAL
CAUTION: Reserve vacuum in power brake booster
must be pumped down (removed) before removing
master cylinder from booster. This is necessary to
prevent booster from sucking in any contamination
as master cylinder is removed. This can be done
simply by pumping the brake pedal, with the vehi-
cle's engine not running, until a firm feeling brake
pedal is achieved.
(1) With engine not running, pump the brake
pedal until a firm pedal is achieved (4 or 5 strokes).
(2) Remove negative battery cable terminal from
battery.
(3) Remove positive battery cable terminal from
battery.
(4) Remove battery thermal guard shield.
(5) Remove battery clamp, nut and battery from
the battery tray.
Fig. 4 BOOSTER, TORQUE SHAFT AND PEDAL
MOUNTING
1 - PEDAL MOUNTING NUT
2 - BRAKE PEDAL ASSEMBLY
3 - PEDAL MOUNTING NUT
4 - PEDAL TORQUE SHAFT
5 - BOOSTER MOUNTING NUT
6 - BOOSTER BRACKET
7 - POWER BRAKE BOOSTER
8 - BOOSTER BRACKET MOUNTING NUT
5a - 4 BRAKES - BASERG
PEDAL TORQUE SHAFT (Continued)
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SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC BINDS ON
INPUT SHAFT SPLINESClutch disc hub splines damaged
during installationClean, smooth, and lubricate disc and shaft
splines. Replace modular clutch assembly,
or clutch disc, and/or input shaft if splines
are severely damaged.
Input shaft splines rough, damaged. Clean input shaft splines. Then lube.
Corrosion or rust formations on
splines of input shaft and discClean input shaft splines and disc splines,
then lube
CLUTCH DISC RUSTED
TO FLYWHEEL AND/OR
PRESSURE PLATEOccurs in vehicles stored or not
driven for extended period of time.
Also occurs after steam cleaning if
vehicle is not used for extended
period.Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
CLUTCH WILL NOT
DISENGAGE PROPERLYDisc bent, distorted during transaxle
installationReplace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Clutch cover diaphragm spring
damaged during transaxle installationReplace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Release fork bent, loose, or
damagedReplace fork if worn or damaged
Clutch cable (LHD Models) binding
or routed incorrectly.Check and correct cable routing.
Self-adjuster in cable (LHD Models)
not functioning properly, resulting in
excess cable slack.Pull on cable conduit at transaxle (as if
disconnecting cable) to check adjuster
operation.
Air in clutch hydraulic circuit (RHD
models).Allow system to self-bleed or replace
hydraulic components.
Leak in clutch hydraulic circuit (RHD
models).Replace worn/damaged/leaking hydraulic
components.
Clutch pedal requires
excessive force (high
release load).Clutch cable routed incorrectly (LHD
models).Check and correct cable routing.
Clutch cable is worn, having high
friction or drag (LHD model).Replace clutch release cable.
Clutch disc is worn. Replace modular clutch assembly (2.4L
models) or clutch cover and disc (2.5L TD
models) and clutch release cable.
SERVICE DIAGNOSIS - CLUTCH PEDAL NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO FLOORPedal bushings worn out or
inadequate lubricationReplace or lubricate bushings at clutch
pedal pivot or master cylinder pushrod.
Clutch pedal return spring worn out Lubricate or replace return spring
CLUTCH PEDAL
SQUEAKS DURING
OPERATIONClutch release lever pivot stud has
inadequate lubricationLubricate or replace clutch release lever
6a - 6 CLUTCHRG
CLUTCH (Continued)
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(4) Install clutch release bearing/lever assembly
into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seat
release lever to pivot ball(s) (Fig. 27) (Fig. 28). A
ªpopº sound should be heard.Make sure LHD lever
is secured to BOTH pivot balls.Verify proper
engagement by lightly pulling outward on lever at
pivot ball location, and then actuating lever and
bearing to ensure proper operation.MASTER CYLINDER - RHD
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove master cylinder to clutch pedal pin
retainer clip. Disengage pushrod from clutch pedal
pin (Fig. 30).
(3) Disengage master cylinder grommet from cowl
panel.
(4) Remove battery and tray.
(5)Diesel models:Remove windshield wiper mod-
ule assembly. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL)
(6) Discharge Air Conditioning system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT - STANDARD PROCEDURE)
(7) Remove suction/discharge line from evaporator
junction block.
(8) Using tool 6638A, disconnect clutch hydraulic
ªquick-connectº fitting (Fig. 29).
(9) Remove clutch master cylinder tubing from
retainers in engine compartment.
(10) Remove clutch master cylinder from dash
panel/clutch pedal bracket by rotating 45É clockwise
and pulling outward towards engine (Fig. 30).
(11) Carefully guide clutch master cylinder and
hydraulic plumbing from engine compartment.
Fig. 27 Release Bearing and Lever (LHD)
1 - RELEASE BEARING
2 - RELEASE LEVER
Fig. 28 Release Bearing and Lever (RHD)
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 29 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
RGCLUTCH6a-13
CLUTCH RELEASE LEVER AND BEARING (Continued)
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INSTALLATION
(1) Carefully route master cylinder plumbing into
engine compartment as removed and position master
cylinder to dash panel hole.
(2) Rotate master cylinder 45É clockwise, insert
into dash panel hole, engaging clutch pedal bracket.
Rotate master cylinder 45É counter-clockwise, secur-
ing it to pedal bracket (Fig. 30).
(3) Install and secure grommet to dash panel.
(4) Connect pushrod to clutch pedal pin. Install
retainer clip (Fig. 30).
(5) Secure master cylinder plumbing to retainers
in engine compartment.
(6) Connect clutch master cylinder plumbing to
slave cylinder ªquick connectº fitting. An audible
ªclickº should be heard. Verify connection by pulling
outward.(7) Connect A/C suction/discharge line to evapora-
tor junction block.
(8)Diesel models:Install wiper module assembly.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION)
(9) Install battery and tray.
(10) Connect battery negative cable
(11) Charge Air Conditioning system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE)
MODULAR CLUTCH ASSY -
2.4L GAS
REMOVAL
(1) Remove transaxle from vehicle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
REMOVAL)
(2) Remove modular clutch assembly from input
shaft (Fig. 31).
Fig. 30 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH ROD
Fig. 31 Modular Clutch Assembly
1 - MODULAR CLUTCH ASSEMBLY
2 - INPUT SHAFT
6a - 14 CLUTCHRG
MASTER CYLINDER - RHD (Continued)
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COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................3
COOLING SYSTEM LEAK TEST.............3
COOLING SYSTEM FLOW CHECK..........3
COOLING SYSTEM AERATION.............3
COOLING SYSTEM DEAERATION...........3
STANDARD PROCEDURE...................4COOLING SYSTEM - DRAINING............4
COOLING SYSTEM - REFILLING............4
COOLANT - ADDING ADDITIONAL...........4
COOLANT LEVEL CHECK - ROUTINE........5
SPECIFICATIONS.........................6
SPECIAL TOOLS..........................6
ACCESSORY DRIVE.......................7
ENGINE................................13
TRANSMISSION.........................36
COOLING
DESCRIPTION - COOLING SYSTEM
The cooling system components consist of a radia-
tor, electric fan motors, shroud, pressure cap, thermo-
stat, transmission oil cooler, water pump, hoses,
clamps, coolant, and a coolant reserve system to com-
plete the circuit.
DESCRIPTION - HOSE CLAMPS
The cooling system uses spring type hose clamps.
If a spring type clamp replacement is necessary,
replace with the original Mopartequipment spring
type clamp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 1).
OPERATION - COOLING SYSTEM
The engine cooling systems primary purpose is to
maintain engine temperature in a range that will
provide satisfactory engine performance and emission
levels under all expected driving conditions. It also
provides hot water (coolant) for heater performance
and cooling for automatic transmission oil. It does
this by transferring heat from engine metal to cool-
ant, moving this heated coolant to the radiator, and
then transferring this heat to the ambient air.²When engine is cold: thermostat is closed, cool-
ing system has no flow through the radiator. The
coolant bypass flows through the engine only.
²When engine is warm: thermostat is open, cool-
ing system has bypass flow and coolant flow through
radiator.
Coolant flow circuits for the 2.4L and 3.3/3.8L
engines are shown in (Fig. 2).
Fig. 1 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
RSCOOLING7-1
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CONDITION POSSIBLE CAUSES CORRECTIONS
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. (a) Replace belt (auto-tensioned
belts.)
(b) Adjust power steering belt
tension (4 cyl. engine)
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric
pulley4. Replace pulley
DRIVE BELTS - 2.4L
REMOVAL
GENERATOR AND AIR CONDITIONING BELT
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield (Fig. 7).
WARNING: DO NOT ALLOW DRIVE BELT TEN-
SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
(3) Position a wrench on the belt tensioner lug
(Fig. 3).
(4) Release belt tension by rotating the tensioner
clockwise (Fig. 3).
(5) Remove belt.
(1) Carefully return tensioner to its relaxed posi-
tion.
POWER STEERING PUMP
(1) From top of the vehicle, loosen locking nuts (D)
and (F) (Fig. 4).
(2) From under the vehicle, loosen the pivot bolt
(E). Loosen adjusting bolt (G) until belt can be
removed.
Fig. 3 A/C & GENERATOR BELT TENSION RELEASE
1 - BELT TENSIONER
2 - WRENCH
Fig. 4 Power Steering Pump
1 - REAR LOCKING NUT (D)
2 - ADJUSTING BOLT (G)
3 - PIVOT BOLT (E)
4 - FRONT LOCKING NUT (F)
RSACCESSORY DRIVE7-9
DRIVE BELTS (Continued)
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CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
²Excessive wear
²Frayed cords
²Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 5).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
INSTALLATION
GENERATOR AND AIR CONDITIONING BELT
(1) Install belt onto all pulleys except for the
crankshaft (Fig. 6).
(2) Rotate belt tensioner clockwise until belt can
be installed onto the crankshaft pulley (Fig. 3).
Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys (Fig. 6).
(4) Install drive belt shield (Fig. 7) and lower vehi-
cle.
POWER STEERING PUMP
(1) Install belt over crankshaft and power steering
pump pulleys (Fig. 6).
(2) Apply an initial snug torque to fasteners (D),
(E), and (F) (Fig. 4).
(3) Tighten adjusting bolt (G) until the proper ten-
sion obtained (Fig. 4). Refer to Belt Tension Specifi-
cations (Refer to 7 - COOLING/ACCESSORY DRIVE
- SPECIFICATIONS).
(4) Tighten locking nuts (D) and (F) to 54 N´m (40
ft. lbs.) (Fig. 4).
(5) Tighten pivot bolt (E) to 54 N´m (40 ft. lbs.)
(Fig. 4).
ADJUSTMENTS
Satisfactory performance of the belt driven accesso-
ries depends on proper belt tension. Belt tensioning
should be performed with the aid of Special Tool
7198. Because of space limitations in the engine com-
partment, the use of this gauge may be restricted.
Raise the vehicle on a hoist and the remove the
splash shield to gain access to the drive belts, if nec-
essary. Adjust belt tension for either aNeworUsed
belt. For specifications, (Refer to 7 - COOLING/AC-
CESSORY DRIVE - SPECIFICATIONS).
Fig. 5 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
Fig. 6 Accessory Drive Belts - 2.4L
1 - POWER STEERING PUMP PULLEY
2 - BELT TENSIONER
3 - GENERATOR PULLEY
4 - BELT - A/C AND GENERATOR
5 - A/C COMPRESSOR PULLEY
6 - CRANKSHAFT PULLEY
7 - BELT - POWER STEERING
7 - 10 ACCESSORY DRIVERS
DRIVE BELTS - 2.4L (Continued)
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