2001 DODGE TOWN AND COUNTRY Engine

STANDARD PROCEDURES - FITTING PISTONS
The piston and cylinder wall must be clean and
dry. Piston diameter should be measured 90 degrees
to piston pin at size location shown in (Fig. 74). Cyl-
inder bores should be measured halfway down the
cylinder bore and transverse to the engine crankshaft
center line shown in (Fig. 75). Refer to Engine Spec-
ifications (Refer to 9 - ENGINE - SPECIFICA-
TIONS).Pistons and cylinder bores should be
measured at normal room temperature, 21ÉC
(70ÉF).
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the cylinder heads. (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL)
(3) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)(4) Remove the top ridge of cylinder bores with a
reliable ridge reamer, if necessary, before removing
pistons from cylinder block.Be sure to keep tops
of pistons covered during this operation. Pis-
tons and connecting rods must be removed
from top of cylinder block. When removing pis-
ton and connecting rod assemblies from the
engine, rotate crankshaft so that each connect-
ing rod is centered in cylinder bore.
(5) Inspect connecting rods and connecting rod
caps for cylinder identification. Identify them, if nec-
essary (Fig. 76).
(6) Remove connecting rod cap. Install connecting
rod bolt protectors on connecting rod bolts (Fig. 77).
(7) Remove each piston and connecting rod assem-
bly out of the cylinder bore.
NOTE: Be careful not to nick crankshaft journals.
(8) After removal, install bearing cap on the mat-
ing rod.
Fig. 74 Piston Measurement Locations
1 - 39.8 mm (1.56 in. ) 3.3L ENGINE
2 - 33.0 mm (1.29 in.) 3.8L ENGINE
Fig. 75 Checking Cylinder Bore Size
Fig. 76 Identify Connecting Rod to Cylinder
1 - CYLINDER NUMBER
Fig. 77 Connecting Rod Protectors
1 - COVER ROD BOLTS WITH A SUITABLE COVERING WHEN
REMOVING OR INSTALLING PISTON ASSEMBLY
RSENGINE 3.3/3.8L9 - 121
PISTON & CONNECTING ROD (Continued)
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INSTALLATION
(1) Before installing pistons and connecting rod
assemblies into the bore, ensure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 78).
(2) Before installing the ring compressor, ensure
the oil ring expander ends are butted and the rail
gaps located as shown in (Fig. 78).
(3) Lubricate the piston and rings with clean
engine oil. Position a ring compressor over the piston
and rings, and tighten the compressor (Fig. 79).Be
sure position of rings does not change during
this operation.(4) Position upper bearing onto connecting rod.
Lubricate bearing with oil.
(5) Install connecting rod bolt protectors (rubber
hose or equivalent) on the connecting rod bolts (Fig.
79).
(6) The pistons are marked with a ªFº located near
the piston pin. Install piston with this mark posi-
tioned to front of engine on both cylinder banks. The
connecting rod oil squirt hole faces the major thrust
(right) side of the engine block (Fig. 80).
(7) Rotate crankshaft until the connecting rod
journal is located in the center of the cylinder bore.
Insert connecting rod and piston into cylinder bore.
Carefully guide connecting rod over the crankshaft
journal (Fig. 79).
(8) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(9) Install lower bearing shell and connecting rod
cap (Fig. 79). Install nuts on cleaned and oiled rod
bolts and tighten to 54 N´m (40 ft. lbs.) PLUS
1¤4
turn.
(10) Repeat procedure for each piston and connect-
ing rod installation.
(11) Install the cylinder heads. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION)
(12) Install the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION)
(13) Fill engine crankcase with proper oil to cor-
rect level.
(14) Connect negative cable to battery.Fig. 78 Piston Ring End Gap Position
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
9 - 122 ENGINE 3.3/3.8LRS
PISTON & CONNECTING ROD (Continued)
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Fig. 79 PISTON AND CONNECTING ROD INSTALLATION
1 - RING - OIL CONTROL 7 - CAP - CONNECTING ROD
2 - RING - NO. 2 COMPRESSION 8 - BEARING - CONNECTING ROD LOWER
3 - RING - NO. 1 COMPRESSION 9 - CRANKSHAFT JOURNAL PROTECTOR (RUBBER HOSE)
4 - RING - SIDE RAIL UPPER & LOWER 10 - BEARING - CONNECTING ROD UPPER
5 - PISTON RING COMPRESSOR 11 - PISTON AND CONNECTING ROD ASSEMBLY
6 - NUT - CONNECTING ROD 12 - PISTON LOCATION MARK (F = FRONT)
RSENGINE 3.3/3.8L9 - 123
PISTON & CONNECTING ROD (Continued)
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PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Wipe cylinder bore clean. Insert the ring and
push down with piston to ensure squareness in bore
to approximately 12 mm (0.50 in.) from top of cylin-
der bore. Check ring gap with a feeler gauge (Fig.
81). For clearance specification (Refer to 9 - ENGINE
- SPECIFICATIONS).
(2) Check piston ring to groove side clearance (Fig.
82). For clearance specification (Refer to 9 - ENGINE
- SPECIFICATIONS)
REMOVAL
(1) Remove piston and connecting rod. (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECT-
ING ROD - REMOVAL)
Fig. 80 Piston and Connecting Rod Positioning (Front View of Engine)
1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SQUIRT HOLE
Fig. 81 Piston Ring Gap
1 - FEELER GAUGE
9 - 124 ENGINE 3.3/3.8LRS
PISTON & CONNECTING ROD (Continued)
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(2) Remove No. 1 and No.2 piston rings from pis-
ton using a ring expander tool (Fig. 85).
(3) Remove upper oil ring side rail (Fig. 74).
(4) Remove lower oil ring side rail (Fig. 74).
(5) Remove oil ring expander (Fig. 74).
INSTALLATION
(1) Install rings with manufacturers I.D. mark (if
present) facing up, to the top of the piston (Fig. 83).
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. 84).
(3) Install upper side rail first and then the lower
side rail.
(4) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 85).(5) Position piston ring end gaps as shown in (Fig.
86).
(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. 82 Piston Ring Side Clearance
1 - FEELER GAUGE
Fig. 83 Piston Ring Installation
1 - NO. 1 PISTON RING
2 - NO. 2 PISTON RING
3 - SIDE RAIL
4 - OIL RING
5 - SPACER EXPANDER
Fig. 84 Oil Ring Side Rail
1 - SIDE RAIL END
RSENGINE 3.3/3.8L9 - 125
PISTON RINGS (Continued)
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VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove the right front wheel and inner splash
shield.
(4) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)(5) Remove vibration damper bolt.
(6) Insert Special Tool 8450 into crankshaft nose
(Fig. 87).
(7) Position 3-jaw puller Special Tool 1026 on
damper as shown in (Fig. 87). Turn puller forcing
screw until damper releases from crankshaft.
(8) Remove the crankshaft vibration damper.
INSTALLATION
(1) Install crankshaft vibration damper using Spe-
cial Tool 8451 with thrust bearing/washer (Fig. 88).
NOTE: To minimize friction and prolong tool life,
lubricate the threads on the forcing screw of Spe-
cial Tool 8451.
(2) Position vibration damper on crankshaft.
(3) Screw Special Tool 8451 into crankshaft until
the bolt seats. Turn the nut to install damper until it
seats fully.
(4) Remove Special Tool 8451.
(5) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(6) Install inner splash shield and right front
wheel.
(7) Connect negative cable to battery.
Fig. 85 Piston Ring Installation
Fig. 86 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
Fig. 87 Vibration Damper - Removal
1 - SPECIAL TOOL 8450 - INSERT
2 - SPECIAL TOOL 1026-3JAWPULLER
9 - 126 ENGINE 3.3/3.8LRS
PISTON RINGS (Continued)
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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.
89), all others are of molded rubber material.
FRONT MOUNT
REMOVAL
(1) Support the engine and transmission assembly
with a floor jack so it will not rotate.
(2) Remove the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 90).(3) Remove six screws from air dam to allow
access to the front mount screws.
(4) Remove the front engine mount screws and
remove the insulator assembly (Fig. 90).
(5) Remove the front mounting bracket, if neces-
sary (Fig. 90).
INSTALLATION
(1) Install the front mounting bracket, if removed
(Fig. 90).
(2) Install the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 90).
(3) Install the insulator assembly and mounting
screws (Fig. 90).
Fig. 88 Vibration Damper - Installation
1 - SPECIAL TOOL 8451
2 - VIBRATION DAMPER
3 - THRUST BEARING & WASHER
Fig. 89 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
RSENGINE 3.3/3.8L9 - 127
VIBRATION DAMPER (Continued)
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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. 91).
(7) Lower transaxle for access to horizontal bolts.
(8) Remove the horizontal bolts from the mount to
the transaxle (Fig. 92) or (Fig. 93).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.
Fig. 90 Engine Mounting - Front
1 - CROSSMEMBER 5 - BOLT 54 N´m (40 ft. lbs.)
2 - BOLT - 68 N´m (50 ft. lbs.) 6 - NUT - 68 N´m (50 ft. lbs.)
3 - BOLT - 102 N´m (75 ft. lbs.) 7 - MOUNT - ENGINE FRONT
4 - BOLT - 68 N´m (50 ft. lbs.) 8 - BRACKET - ENGINE FRONT MOUNT
9 - 128 ENGINE 3.3/3.8LRS
FRONT MOUNT (Continued)
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