2001 DODGE TOWN AND COUNTRY Service Manual

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DODGE TOWN AND COUNTRY 2001 Service Manual ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION...........................14
DIAGNOSIS AND TESTING.................15
COOLANT CONCENTRATION TESTING......15
STANDARD PROCEDURE..................1

ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION...........................14
DIAGNOSIS AND TESTING.................15
COOLANT CONCENTRATION TESTING......15
STANDARD PROCEDURE..................15
COOLANT SERVICE.....................15
ADDING ADDITIONAL COOLANT...........15
COOLANT LEVEL CHECK................16
REFILLING COOLING SYSTEM............16
DRAINING COOLING SYSTEM.............16
COOLANT RECOVERY PRESS CONTAINER
DESCRIPTION...........................17
OPERATION.............................17
REMOVAL..............................18
INSTALLATION...........................18
ENGINE COOLANT TEMP SENSOR
DESCRIPTION...........................19
OPERATION.............................19
REMOVAL..............................19
INSTALLATION...........................19
ENGINE COOLANT THERMOSTAT
DESCRIPTION...........................19
OPERATION.............................19
REMOVAL..............................19
INSTALLATION...........................20
RADIATOR
DESCRIPTION...........................20
OPERATION.............................20
REMOVAL..............................20
INSTALLATION...........................21
RADIATOR DRAINCOCK
REMOVAL..............................22INSTALLATION...........................22
WATER PUMP
DESCRIPTION...........................22
OPERATION.............................22
REMOVAL..............................22
CLEANING..............................23
INSTALLATION...........................23
RADIATOR PRESSURE CAP
DESCRIPTION...........................24
OPERATION.............................24
DIAGNOSIS AND TESTING.................25
COOLING SYSTEM PRESSURE CAP........25
PRESSURE RELIEF TEST................25
CLEANING..............................25
INSPECTION............................26
RADIATOR FAN
DESCRIPTION...........................26
OPERATION.............................26
DIAGNOSIS AND TESTING.................26
RADIATOR FAN MOTOR.................26
REMOVAL..............................27
INSTALLATION...........................27
HOSE CLAMPS
DESCRIPTION...........................27
OPERATION.............................28
RADIATOR FAN RELAY
DESCRIPTION...........................28
OPERATION.............................28
COOLANT SYSTEM HOSES
REMOVAL..............................28
INSTALLATION...........................29
COOLANT
DESCRIPTION
Coolant flows through the engine water jackets
and cylinder heads absorbing heat produced by the
engine during operation. The coolant carries heat to
the radiator and heater core. Here it is transferred to
ambient air passing through the radiator and heater
core fins.
The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle oper-
ating conditions. The recommended mixture of 50/50
ethylene-glycol and water will provide protectionagainst freezing to -37 deg. C (-35 deg. F). The anti-
freeze concentrationmust alwaysbe a minimum of
44 percent, year-round in all climates.If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7 deg. C (-90 deg. F). A
higher percentage will freeze at a warmer tempera-
ture. Also, a higher percentage of antifreeze can
cause the engine to overheat because the specific
heat of antifreeze is lower than that of water.
7a - 14 ENGINERG
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DODGE TOWN AND COUNTRY 2001 Service Manual 100 Percent Ethylene-GlycolÐShould Not Be Used in
Chrysler Vehicles
Use of 100 percent ethylene-glycol will cause for-
mation of additive deposits in the system, as the cor-
rosion inhibitive additiv

100 Percent Ethylene-GlycolÐShould Not Be Used in
Chrysler Vehicles
Use of 100 percent ethylene-glycol will cause for-
mation of additive deposits in the system, as the cor-
rosion inhibitive additives in ethylene-glycol require
the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise to as high as
149 deg. C (300 deg. F). This temperature is hot
enough to melt plastic and soften solder. The
increased temperature can result in engine detona-
tion. In addition, 100 percent ethylene-glycol freezes
at -22 deg. C (-8 deg. F ).
Propylene-glycol FormulationsÐShould Not Be Used in
Chrysler Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications.It's overall effec-
tive temperature range is smaller than that of ethyl-
ene-glycol. The freeze point of 50/50 propylene-glycol
and water is -32 deg. C (-26 deg. F). 5 deg. C higher
than ethylene-glycol's freeze point. The boiling point
(protection against summer boil-over) of propylene-
glycol is 125 deg. C (257 deg.F)at96.5 kPa (14 psi),
compared to 128 deg. C (263 deg. F) for ethylene-gly-
col. Use of propylene-glycol can result in boil-over or
freeze-up in Chrysler vehicles, which are designed for
ethylene-glycol. Propylene glycol also has poorer heat
transfer characteristics than ethylene glycol. This
can increase cylinder head temperatures under cer-
tain conditions.
Propylene-glycol/Ethylene-glycol MixturesÐShould Not Be
Used in Chrysler Vehicles
Propylene-glycol/ethylene-glycol Mixtures can
cause the destabilization of various corrosion inhibi-
tors, causing damage to the various cooling system
components. Also, once ethylene-glycol and propy-
lene-glycol based coolants are mixed in the vehicle,
conventional methods of determining freeze point will
not be accurate. Both the refractive index and spe-
cific gravity differ between ethylene glycol and propy-
lene glycol.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.DIAGNOSIS AND TESTING - COOLANT
CONCENTRATION TESTING
Coolant concentration should be checked when any
additional coolant was added to system or after a
coolant drain, flush and refill. The coolant mixture
offers optimum engine cooling and protection against
corrosion when mixed to a freeze point of -37ÉC
(-34ÉF) to -59ÉC (-50ÉF). The use of a hydrometer or a
refractometer can be used to test coolant concentra-
tion.
A hydrometer will test the amount of glycol in a
mixture by measuring the specific gravity of the mix-
ture. The higher the concentration of ethylene glycol,
the larger the number of balls that will float, and
higher the freeze protection (up to a maximum of
60% by volume glycol).
A refractometer will test the amount of glycol in a
coolant mixture by measuring the amount a beam of
light bends as it passes through the fluid.
Some coolant manufactures use other types of gly-
cols into their coolant formulations. Propylene glycol
is the most common new coolant. However, propylene
glycol based coolants do not provide the same freez-
ing protection and corrosion protection and is not rec-
ommended.
CAUTION: Do not mix types of coolantÐcorrosion
protection will be severely reduced.
STANDARD PROCEDURE - COOLANT SERVICE
For engine coolant recommended service schedule,
(Refer to LUBRICATION & MAINTENANCE/MAIN-
TENANCE SCHEDULES - DESCRIPTION).
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The pressure/vent cap should not be removed
from the coolant recovery pressure container.
When additional coolant is needed to maintain this
level, it should be added to the coolant recovery pres-
sure container (Fig. 1). Use only 50/50 mix of ethyl-
ene glycol type antifreeze and distilled water. For the
recommeded antifreeze/coolant type (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
RGENGINE7a-15
COOLANT (Continued)
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DODGE TOWN AND COUNTRY 2001 Service Manual STANDARD PROCEDURE - COOLANT LEVEL
CHECK
NOTE: Do not remove pressure/vent cap for routine
coolant level inspections.
The coolant reserve system provides a quick visual
method for determining the cool

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DODGE TOWN AND COUNTRY 2001 Service Manual COOLANT RECOVERY PRESS
CONTAINER
DESCRIPTION
The coolant recovery pressure container is
mounted in the engine compartment next to the bat-
tery. The coolant recovery pressure container is made
of plas

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DODGE TOWN AND COUNTRY 2001 Service Manual REMOVAL
(1) Drain cooling system below level of coolant
recovery pressure bottle. (Refer to 7 - COOLING/EN-
GINE/COOLANT - STANDARD PROCEDURE)
(2) Disconnect coolant bypass and overflow hoses
from coo

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DODGE TOWN AND COUNTRY 2001 Service Manual ENGINE COOLANT TEMP
SENSOR
DESCRIPTION
The engine coolant temperature sensor threads
into a coolant passage in the cylinder head (Fig. 7).
New sensors have sealant applied to the threads.
OPERATION
Th

ENGINE COOLANT TEMP
SENSOR
DESCRIPTION
The engine coolant temperature sensor threads
into a coolant passage in the cylinder head (Fig. 7).
New sensors have sealant applied to the threads.
OPERATION
The coolant temperature (ECT) sensor is a nega-
tive temperature coefficient (NTC) thermistor (resis-
tance varies inversley with temperature). This means
at cold tempertures its resistance is high so the volt-
age signal will be high. As coolant temperture
increases, resistance decreases and the signal voltage
will be low. This allows the sensor to provide an ana-
log voltage signal to the ECM.
REMOVAL
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE/VENT CAP, CYLINDER
BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN
THE SYSTEM IS HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
(1) Drain the cooling system. (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE).
(2) Disconnect coolant temperature sensor electri-
cal connector (Fig. 8).
(3) Remove coolant temperature sensor from cylin-
der head (Fig. 8).
INSTALLATION
(1) Install coolant temperature sensor in cylinder
head (Fig. 8).
(2) Connect coolant temperature sensor electrical
connector (Fig. 8).
(3) Refill the cooling system. (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE).
(4) Connect the negative battery cable.
ENGINE COOLANT
THERMOSTAT
DESCRIPTION
A pellet-type thermostat controls the operating
temperature of the engine by controlling the amount
of coolant flow to the radiator (Fig. 9).
OPERATION
The thermostat starts to open at 80ÉC (176ÉF).
Above this temperature, coolant is allowed to flow to
the radiator. This provides quicker engine warmup
and overall temperature control.
The same thermostat is used for winter and sum-
mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes other prob-
lems. These are: longer engine warmup time, unreli-
able warmup performance, increased exhaust
emissions and crankcase condensation. This conden-
sation can result in sludge formation.
REMOVAL
NOTE: The thermostat is not serviced separately.
The thermostat and housing must be replaced as
an assembly.
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove front wiper unit to gain access to ther-
mostat housing(Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL).
Fig. 8 COOLANT TEMPERATURE SENSOR
LOCATION
1 - EGR SOLENOID
2 - UPPER RADIATOR HOSE
3 - COOLANT TEMPERATURE SENSOR
4 - INTAKE MANIFOLD INLET
5 - INTAKE MANIFOLD/CYLINDER HEAD COVER
RGENGINE7a-19
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DODGE TOWN AND COUNTRY 2001 Service Manual (4) Disconnect upper radiator hose adapter tube,
water pump hose, and EGR hose at thermostat hous-
ing.
(5) Remove both thermostat housing attaching
bolts and housing (Fig. 10).
INSTALLATION
(1) Insta

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DODGE TOWN AND COUNTRY 2001 Service Manual (4) Remove the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(5) Disconnect coolant bypass hose (Fig. 11).
(6) Disconnect upper and lower hoses from the
radiator (Fig. 11).
(7

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