2001 DODGE TOWN AND COUNTRY brake sensor

DESCRIPTION TORQUE*
STRIP-OUT REPAIR SCREWS ONLY
MAP Sensor Repair
Screw4 N´m (35 in. lbs.)
Power Steering Reservoir
Repair Screw9 N´m (80 in. lbs.)
EGR Tube Attaching
Repair Screw9 N´m (80 in. lbs.)
Throttle Cable Bracket
Repair Screw9 N´m (80 in. lbs.)
*Install Slowly Using Hand Tools Only
STANDARD PROCEDURE - INTAKE MANIFOLD
VACUUM PORT REPAIR
The composite intake manifold vacuum ports can
be repaired. Although, if the manifold plenum cham-ber is damaged or cracked, the manifold must be
replaced.
To repair a broken or damaged vacuum nipple
(port) on the composite intake manifold, perform the
following procedure:
PARTS REQUIRED TOOLS REQUIRED
Brass Nipple ± 1/49O.D.
x 1/89pipe thread
(LDP/Speed Control Port)Pipe Tap ± 1/49-18NPT
& 1/89-18NPT
Brass Nipple ± 1/29O.D.
x 1/49pipe thread (Brake
Booster Port)Drill Bit ± 7/169& 11/329
File/Sand Paper
NOTE: While performing this procedure, avoid get-
ting the manifold material residue into the plenum
chamber.
(1) File or sand the remaining port back until a
flat surface is obtained (plane normal to nipple (port)
axis).
Fig. 120 INTAKE MANIFOLD - UPPER 3.8L
1 - BRACKET - THROTTLE CABLE
2 - BOLT
3 - SCREW
4 - MAP SENSOR
5 - MANIFOLD - UPPER
6 - WIRE HARNESS
7 - GASKET (1 PER CYL. BANK)
8 - Bolt
Fig. 121 INTAKE MANIFOLD - LOWER
1 - INTAKE MANIFOLD - LOWER
2 - BOLT - GASKET END SEAL RETAINER
3 - GASKET
4 - BOLT - LOWER INTAKE MANIFOLD
9 - 142 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER 3.3L (Continued)
ProCarManuals.com

(2) Drill out the nipple (port) base using a 7/16º
(brake booster port) or 11/32º (LDP/speed control
port) drill bit (Fig. 122).
(3) Using a 1/4º±18 NPT (brake booster port) or
1/8º±18 NPT (LDP/speed control port ) pipe tap, cut
internal threads (Fig. 122). Use caution to start tap
in a axis same as original nipple.
(4) Apply MopartThread Sealant to threads of
repair nipple(s).
(5) Install repair nipple(s). Do not over torque
repair nipple(s).
REMOVAL - 3.3L
(1) Disconnect battery negative cable.
(2) Disconnect air inlet sensor electrical connector.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/IN-
LET AIR TEMPERATURE SENSOR - COMPONENT
LOCATION)
(3) Remove air inlet resonator to throttle body
hose assembly.
(4) Remove throttle and speed control cables.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - REMOVAL)
(5) Disconnect make-up air hose support clip from
throttle cable bracket.
(6) Disconnect the automatic idle speed (AIS)
motor and throttle position sensor (TPS) wiring con-
nectors from throttle body. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - COMPONENT
LOCATION)
(7) Disconnect the manifold absolute pressure
(MAP) sensor electrical connector. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/MAP SENSOR -
COMPONENT LOCATION)
(8) Disconnect the EGR transducer vacuum hose
from bottom of upper intake manifold (Fig. 123).
(9) Remove the EGR tube (Fig. 123).
(10) Disconnect the vapor purge vacuum hose from
throttle body.
(11) Disconnect the PCV hose (Fig. 124).
(12) Remove the power steering reservoir attach-
ing bolts and only loosen the nut (Fig. 125). Lift res-
ervoir up to disengage lower mount from stud. Set
reservoir aside.Do notdisconnect hose.
(13) Disconnect the brake booster and leak detec-
tion pump (LDP) hoses from intake manifold (Fig.
126).
NOTE: The cover on the upper intake manifold
should never be removed under any circumstance.
The fasteners attaching the upper intake manifold
can be accessed without removing this cover.
(14) Remove intake manifold bolts and remove the
manifold (Fig. 127).
(15) Cover the lower intake manifold with a suit-
able cover while the upper manifold is removed.
(16) Clean and inspect the upper intake manifold.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - CLEANING) (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - INSPECTION)
Fig. 122 Intake Manifold Port Repair
1 - BRAKE BOOSTER PORT = 1/49±18 NPT PIPE TAP
1 - LDP/SPEED CONTROL PORT = 1/89±18 NPT PIPE TAP
2 - DRILL BIT = 7/169BRAKE BOOSTER PORT
2 - DRILL BIT = 11/329LDP/SPEED CONTROL PORT
3 - INTAKE MANIFOLD
Fig. 123 EGR COMPONENTS - 3.3L
1 - BOLT
2 - EGR VALVE ASSEMBLY
3 - EGR TUBE
RSENGINE 3.3/3.8L9 - 143
INTAKE MANIFOLD - UPPER 3.3L (Continued)
ProCarManuals.com

CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check manifold for:
²Damage and cracks.
²Mounting surface distortion by using a straight-
edge and thickness gauge.
INSTALLATION - 3.3L
(1) If the following components were removed from
manifold, install and tighten to specifications:
CAUTION: The special screws used for the compos-
ite manifold attached components must be installed
slowly using hand tools only. This requirement is to
prevent the melting of material that causes stripped
threads. If threads become stripped, an oversize
repair screw is available. For more information and
procedure (Refer to 9 - ENGINE/MANIFOLDS/IN-
TAKE MANIFOLD - STANDARD PROCEDURE).
²MAP sensor - 1.7 N´m (15 in. lbs.)
²Throttle cable bracket - 5.6 N´m (50 in. lbs.)
(2) Remove covering on lower intake manifold and
clean surfaces.
(3) Inspect manifold gasket condition. Gaskets can
be re-used, if not damaged. To replace, remove gasket
from upper manifold (Fig. 127). Position new gasket
in seal channel and press lightly in-place. Repeat
procedure for each gasket position.
Fig. 124 PCV & HOSE
1 - HOSE - PCV
2 - P C V VA LV E
Fig. 125 POWER STEERING FLUID RESERVOIR
1 - POWER STEERING RESERVOIR
2 - BOLT - RESERVOIR TO MANIFOLD
3 - NUT - RESERVOIR TO COIL BRACKET
Fig. 126 BRAKE BOOSTER & LDP VACUUM HOSES
1 - LDP & SPEED CONTROL VACUUM HOSE
2 - BRAKE BOOSTER VACUUM HOSE
3 - MAP SENSOR
9 - 144 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER 3.3L (Continued)
ProCarManuals.com

(4) Position upper manifold on lower manifold (Fig.
127). Install and tighten bolts to 12 N´m (105 in. lbs.)
following torque sequence in (Fig. 128).(5) Connect the MAP sensor electrical connector.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
MAP SENSOR - COMPONENT LOCATION)
(6) Connect the brake booster and LDP vacuum
hose to intake manifold (Fig. 126).
CAUTION: The special screws used for attaching
the EGR tube and power steering reservoir to the
manifold must be installed slowly using hand tools
only. This requirement is to prevent the melting of
material that causes stripped threads. If threads
become stripped, an oversize repair screw is avail-
able. For more information and procedure (Refer to
9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - STAN-
DARD PROCEDURE).
(7) Install the power steering reservoir (Fig. 125).
Tighten screws to manifold to 5.6 N´m (50 in. lbs.).
(8) Using new gaskets, install the EGR tube and
torque bolts to 5.6 N´m (50 in. lbs.).
(9) Connect the EGR transducer vacuum hose.
(10) Install throttle and speed control cables.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - INSTALLATION)
(11) Attach make up air hose clip into the hole in
the throttle cable bracket.
(12) Connect the wiring connectors to the throttle
position sensor (TPS) and Automatic Idle Speed (AIS)
motor. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE
MANIFOLD - COMPONENT LOCATION)
(13) Install air cleaner and air inlet hose assembly.
(14) Connect the inlet air sensor electrical connec-
tor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/INLET AIR TEMPERATURE SENSOR -
COMPONENT LOCATION)
(15) Connect battery negative cable.
INTAKE MANIFOLD - UPPER
3.8L
REMOVAL - 3.8L
(1) Disconnect battery negative cable.
(2) Disconnect air inlet sensor electrical connector.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/IN-
LET AIR TEMPERATURE SENSOR - COMPONENT
LOCATION)
(3) Remove air inlet resonator to throttle body
hose assembly.
(4) Remove throttle and speed control cables.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - REMOVAL)
(5) Disconnect make-up air hose support clip from
throttle cable bracket.
(6) Disconnect the automatic idle speed (AIS)
motor and throttle position sensor (TPS) wiring con-
Fig. 127 INTAKE MANIFOLD - UPPER 3.3L
1 - BOLT
2 - MAP SENSOR
3 - SCREW
4 - MANIFOLD - UPPER
5 - WIRE HARNESS
6 - GASKET (3 PER CYL. BANK)
Fig. 128 UPPER MANIFOLD TIGHTENING
SEQUENCE
RSENGINE 3.3/3.8L9 - 145
INTAKE MANIFOLD - UPPER 3.3L (Continued)
ProCarManuals.com

nectors from throttle body. (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - COMPONENT
LOCATION)
(7) Disconnect the manifold absolute pressure
(MAP) sensor electrical connector. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/MAP SENSOR -
COMPONENT LOCATION)
(8) Disconnect the EGR transducer vacuum hose
from bottom of upper intake manifold (Fig. 129).
(9) Remove the EGR tube (Fig. 129).
(10) Disconnect the vapor purge vacuum hose from
throttle body.
(11) Disconnect the PCV hose (Fig. 130).
(12) Remove the power steering reservoir attach-
ing bolts and loosen the nut only (Fig. 131). Lift res-
ervoir up to disengage lower mount from stud. Set
reservoir aside.Do notdisconnect hose.
(13) Disconnect the brake booster and leak detec-
tion pump (LDP) hoses from intake manifold (Fig.
132).
(14) Remove intake manifold bolts and remove the
manifold (Fig. 133).
(15) Cover the lower intake manifold with a suit-
able cover when servicing.
(16) Clean and inspect the upper intake manifold.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - CLEANING) (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - INSPECTION)
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
Fig. 129 EGR COMPONENTS - 3.8L
1 - EGR TUBE WITH BOLTS
2 - EGR VALVE ASSEMBLY
Fig. 130 PCV & HOSE
1 - HOSE - PCV
2 - P C V VA LV E
Fig. 131 POWER STEERING FLUID RESERVOIR
1 - POWER STEERING RESERVOIR
2 - BOLT - RESERVOIR TO MANIFOLD
3 - NUT - RESERVOIR TO COIL BRACKET
9 - 146 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER 3.8L (Continued)
ProCarManuals.com

INSPECTION
Check manifold for:
²Damage and cracks.
²Mounting surface distortion by using a straight-
edge and thickness gauge.
INSTALLATION - 3.8L
(1) If the following components were removed from
manifold, install and tighten to specifications:
²MAP sensor - 3.4 N´m (30 in. lbs.)
²Throttle cable bracket - 12 N´m (105 in. lbs.)
(2) Remove covering on lower intake manifold and
clean surfaces.
(3) Position the new intake manifold gasket on
lower manifold.
(4) Position upper manifold on lower manifold (Fig.
133). Install and tighten bolts to 12 N´m (105 in. lbs.)
following torque sequence in (Fig. 134).
(5) Connect the MAP sensor electrical connector.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
MAP SENSOR - COMPONENT LOCATION)
(6) Connect the brake booster and LDP vacuum
hose to intake manifold (Fig. 132).
(7) Connect the PCV hose (Fig. 130).
(8) Install the power steering reservoir (Fig. 131)
and torque fasteners to 12 N´m (105 in. lbs.).
(9) Connect the EGR transducer vacuum hose.
(10) Using new gaskets, install the EGR tube (Fig.
129) and torque bolts to 12 N´m (105 in. lbs.).
Fig. 132 BRAKE BOOSTER & LDP VACUUM HOSES
1 - LDP & SPEED CONTROL VACUUM HOSE
2 - BRAKE BOOSTER VACUUM HOSE
3 - MAP SENSOR
Fig. 133 INTAKE MANIFOLD - UPPER 3.8L
1 - BRACKET - THROTTLE CABLE
2 - BOLT
3 - SCREW
4 - MAP SENSOR
5 - MANIFOLD - UPPER
6 - WIRE HARNESS
7 - GASKET (1 PER CYL. BANK)
8 - BOLT
Fig. 134 UPPER MANIFOLD TIGHTENING
SEQUENCE
RSENGINE 3.3/3.8L9 - 147
INTAKE MANIFOLD - UPPER 3.8L (Continued)
ProCarManuals.com

(10) Disconnect high pressure line at pump (Fig.
5).
(11) Disconnect power steering pump return hose
clamp (Fig. 5).
(12) Remove power steering return line retaining
clamp (Fig. 5).
(13) Remove power steering line clamps from oil
pan (Fig. 5).
(14) Remove power steering pump reservoir and
bracket (Fig. 5).
(15) Drain coolant system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(16) Remove coolant pressure tank (Fig. 6).
(17) Remove battery shield.
(18) Remove charge air cooler outlet hose.
(19) Remove charge air cooler inlet hose (Fig. 7).
(20) Disconnect upper radiator hose at engine (Fig.
8).
(21) Disconnect lower radiator hose at engine (Fig.
8).
(22) Disconnet brake booster vacuum supply hose.
(23) Disconnect heater core return hose at engine.
Fig. 4 MASS AIR FLOW (MAF) SENSOR LOCATION
1 - MAF SENSOR ELECTRICAL CONNECTOR
2 - RETAINING CLAMPS
3 - MASS AIR FLOW (MAF) SENSOR
4 - AIR CLEANER HOUSING
Fig. 5 RESERVOIR AND HOSES - 2.5L DIESEL
1 - RESERVOIR
2 - RESERVOIR BRACKET
3 - SUPPLY HOSE BRACKET
4 - RETURN HOSE FROM GEAR
5 - ROUTING CLIP
6 - PRESSURE HOSE TO GEAR
7 - SUPPLY HOSE (PUMP END)
8 - PRESSURE HOSE (PUMP END)
9 - SUPPLY HOSE
10 - RETURN HOSE
Fig. 6 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
9a - 4 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L TURBO DIESEL (Continued)
ProCarManuals.com

(24) Disconnect egr solenoid vacuum line at brake
booster check valve.
(25) Disconnect fuel injector, cam sensor, boost
pressure/intake air temp sensor, fuel rail high pres-
sure, and egr solenoid connectors (Fig. 9).
(26) Disconnect generator electrical connectors.
(27) Disconnect coolant temp sensor and glow plug
electrical connectors.
(28) Disconnect injection pump and A/C compres-
sor electrical connectors.
(29) Disconnect starter electrical connectors.
(30) Disconnect ground wires at engine block.
(31) Raise vehicle on hoist.
(32) Disconnect oil temp sensor, oil pressure sen-
sor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 10).
(33) Remove front wheels.
(34) Remove the suspension cradle assembly (Refer
to 13 - FRAME & BUMPERS/FRAME/ENGINE
CRADLE CROSSMEMBER - REMOVAL).
(35) Remove both axle shaft assemblies (Refer to 3
- DIFFERENTIAL & DRIVELINE/HALF SHAFT -
REMOVAL).(36) Disconnect the clutch slave cylinder quick dis-
connect line (RHD only)(Refer to 6 - CLUTCH/SLAVE
CYLINDER - REMOVAL).
(37) Disconnect reverse lamp connector.
(38) Disconnect shifter cables at the tranmission
(Refer to 21 - TRANSMISSION/TRANSAXLE/MAN-
UAL/GEAR SHIFT CABLE - REMOVAL).
(39) Disconnect exhaust pipe from the turbo-
charger downpipe and reposition to right side of vehi-
cle.
(40) Disconnect cabin heater coolant line (Refer to
24 - HEATING & AIR CONDITIONING/CABIN
HEATER/HEATER UNIT - REMOVAL).
(41) Remove front engine mount bracket retaining
bolts from lower radiator support
(42) Lower vehicle. Evacuate the A/C system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT - STANDARD PROCE-
DURE).
(43) Disconnect the A/C lines at the A/C compres-
sor.
(44) Disconnect the fuel supply and return lines.
(45) Position engine cradle under engine and lower
vehicle over cradle.
(46) Remove right engine mount bolts.
Fig. 7 CHARGE AIR COOLER HOSES
1 - COOLING MODULE
2 - BYPASS HOSE
3 - UPPER RADIATOR HOSE
4 - CHARGE AIR COOLER OULET HOSE
5 - CHARGE AIR COOLER INLET HOSE
6 - LOWER RADIATOR HOSE
7 - CHARGE AIR COOLER
Fig. 8 UPPER AND LOWER RADIATOR HOSES
1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET
RGENGINE 2.5L TURBO DIESEL9a-5
ENGINE 2.5L TURBO DIESEL (Continued)
ProCarManuals.com